Particles, particle dispersion, particle-dispersed resin composition, producing method therefor, resin molded article, producing method therefor, catalyst particles, catalyst solution, catalyst composition, catalyst molded article, titanium complex, titanium oxide particles and producing method therefor

ABSTRACT

Organic-inorganic composite particles that can be dispersed in a solvent and/or a resin as primary particles having an organic group on the surface of inorganic particles, the organic-inorganic composite particles having negative birefringence.

This is a divisional of U.S. application Ser. No. 13/640,911 filed Dec.31, 2012, which is a national stage of PCT/JP2011/059040 filed Apr. 11,2011, which claims priority from Japanese Patent Application Nos.2010-091577, filed on Apr. 12, 2010; 2010-172310, filed on Jul. 30,2010; 2010-172309 filed on Jul. 30, 2010; 2011-086371 filed Apr. 8,2011; 2011-086701 filed Apr. 8, 2011; and 2011-086803 filed Apr. 8,2011, the contents of all of which are hereby incorporated by referenceinto this application.

TECHNICAL FIELD

The present invention relates to particles, a particle dispersion, aparticle-dispersed resin composition and a resin molded article, andmore particularly to a particle dispersion, a particle-dispersed resincomposition and a resin molded article that are for use in variousapplications including optical applications, and particles that can bedispersed therein.

The present invention also relates to a particle-dispersed resincomposition, a particle-dispersed resin molded article, and producingmethods therefor.

The present invention also relates to catalyst particles, a catalystsolution, a catalyst composition and a catalyst molded article, and moreparticularly to catalyst particles, a catalyst solution, a catalystcomposition and a catalyst molded article that have a catalytic action.

The present invention also relates to a resin molded article and aproducing method therefor.

The present invention also relates to a titanium complex, titanium oxideparticles and a producing method therefor, and more particularly to atitanium oxide particle producing method, a titanium complex that can beused in the producing method, and titanium oxide particles prepared bythe producing method.

BACKGROUND ART

It is conventionally known that nanometer-sized particles(nanoparticles) are used in optical materials.

For example, a method has been proposed in which organomodified fineparticles are obtained by subjecting fine particles of a metal oxidesuch as SiO₂ or TiO₂ and an organic modifier to a hydrothermal synthesis(see, for example, Patent Document 1 listed below).

Also, it is long known that oxides such as titanium oxide exert aphotocatalytic action.

For example, it is known that oxides such as titanium oxide, strontiumtitanate and tungsten oxide decompose organic substances by theirphotocatalytic action (see, for example, Non-Patent Document 1 listedbelow).

It is also long known that porous resin obtained by porosifying resinexhibits various physical properties due to porosification, in additionto the physical properties inherent to resin.

For example, a method has been proposed in which porous polyimide resinis obtained by blending polyethylene glycol dimethyl ether with apolyimide resin precursor so as to prepare a mixed resin solution,forming a coating and then bringing the coating into contact with hothigh pressure carbon dioxide so as to extract polyethylene glycoldimethyl ether (see, for example, Patent Document 2 listed below).

The porous polyimide resin disclosed in Patent Document 2 has uniformlyformed pores (cells), and the dielectric constant of the porouspolyimide resin is set lower than that of non-porous polyimide resin.

It is also long known that titanium oxide particles for use in variousindustrial products are prepared in organic solvents or the like.Meanwhile, from a view point of reducing the environmental load inrecent years, various methods are being studied to prepare titaniumoxide particles in water, which imposes little load to the environmentas compared to organic solvents or the like.

To produce such titanium oxide, for example, a titanium oxide particleproducing method has been proposed in which titanium oxide particles areprepared by treating a titanium complex containing glycolic acid as aligand in hot high pressure water (see, for example, Non-Patent Document2 listed below).

CITATION LIST Patent Documents

-   Patent Document 1: Japanese Unexamined Patent Publication No.    2005-194148-   Patent Document 2: Japanese Unexamined Patent Publication No.    2003-26850 Non-Patent Documents-   Non-Patent Document 1: Journal of Surface Science Society of Japan,    vol. 24, No. 1, pp. 13 to 18, 2003-   Non-Patent Document 2: Koji Tomita et al., “A Water-Soluble Titanium    Complex for the Selective Synthesis of Nanocrystalline Brookite,    Rutile, and Anatase by a Hydrothermal Method”, Angewandte Chemie    Int. Ed., 2006, vol. 45, pp. 2378 to 2381

DISCLOSURE OF THE INVENTION Problems to be Solved

Particles for use in the above-described applications are required tohave various characteristics, in addition to excellent opticalcharacteristics.

Also, depending on the combination of organomodified fine particles andresin, a problem may arise in that the organomodified particlescoagulate.

Also, depending on the application and purpose of catalysts, there arecases where after preparation of a catalyst resin composition byblending the oxide proposed in Non-Patent Document 1 mentioned abovewith a resin, a molded article is formed of the catalyst resincomposition.

The molded article, however, is problematic in that it is easilydegraded by the catalytic action of the oxide because the resin is incontact with the oxide in the molded article.

Also, there is another problem in that the oxide easily coagulates inthe resin during preparation of the resin composition, resulting in poorclarity.

Meanwhile, in recent years, there is demand for porous resin havingsmall-sized pores (cells). To address this demand, for example, attemptsare made in which inorganic fine particles having a small particle sizeare blended with resin, and thereafter the inorganic fine particles areextracted.

However, blending inorganic fine particles with resin results incoagulation of the inorganic fine particles in the resin. Consequently,small-sized pores (cells) cannot be formed, and thus the porous resinwill be opaque. Furthermore, the mechanical strength of the porous resinis insufficient and flexibility is poor, as a result of which a problemarises in that it is not possible to form a self-standing film.

Also, there is demand of wanting to design the arrangement of pores(cells) in porous resin.

Normally, titanium oxide particles are white, but the titanium oxideparticles prepared by the titanium oxide particle producing methoddisclosed in Non-Patent Document 2 described above are colored (brown)due to a decomposition product of the ligand (decomposition product ofglycolic acid) of the titanium complex that has been decomposed in hothigh pressure water.

Also, in the case of preparing nano-sized titanium oxide particles, itis very difficult to separate the titanium oxide particles from thewater-soluble ligand (glycolic acid) remaining from the production ofthe titanium complex.

For this reason, in the case of using such titanium oxide particles inoptical applications, it is necessary to remove the color of thetitanium oxide particles (the decomposition product of the ligand) andthe residual ligand, which makes the titanium oxide particle producingprocess complex.

A first object of the present invention is to provide particles thathave excellent optical characteristics and excellent dispersibility, aparticle dispersion, a particle-dispersed resin composition and a resinmolded article.

A second object of the present invention is to provide aparticle-dispersed resin composition that contains organic-inorganiccomposite particles uniformly dispersed in a resin, a particle-dispersedresin molded article, and producing methods therefor.

A third object of the present invention is to provide catalyst particlesthat have excellent dispersibility in a solvent and/or a resin, acatalyst solution in which catalyst particles are dispersed in a solventand that has excellent clarity, and a catalyst composition and acatalyst molded article in which degradation of the resin is suppressedand that have excellent clarity.

A fourth object of the present invention is to provide a resin moldedarticle that has excellent clarity and excellent mechanical strength,and a producing method therefor.

A fifth object of the present invention is to provide a titanium oxideparticle producing method with which the environmental load as well ascoloring of titanium oxide particles can be reduced, a titanium complexthat can be used in the producing method, and titanium oxide particlesprepared by the producing method.

Means for Solving the Problem

A first group of inventions for achieving the first object is asfollows.

Specifically, particles according to the present invention areorganic-inorganic composite particles that can be dispersed in a solventand/or a resin as primary particles having an organic group on thesurface of inorganic particles, the organic-inorganic compositeparticles having negative birefringence.

Also, with the particles of the present invention, it is preferable thatthe inorganic particles are composed of a carbonate containing analkaline earth metal and/or a composite oxide containing an alkalineearth metal.

Also, with the particles of the present invention, it is preferable thatthe primary particles are obtained by surface-treating the inorganicparticles with an organic compound, and the organic compound contains abinding group capable of binding to the surface of the inorganicparticles and a hydrophobic group and/or a hydrophilic group serving asthe organic group.

Also, it is preferable that the particles of the present invention havean aspect ratio of 1000 or less.

Also, it is preferable that the particles of the present invention havea maximum length of 200 μm or less.

Also, it is preferable that the particles of the present invention areobtained by hydrothermal synthesis.

Also, with the particles of the present invention, it is preferable thatan inorganic compound for forming inorganic particles and the organiccompound are subjected to a hydrothermal synthesis.

Also, with the particles of the present invention, it is preferable thata metal hydroxide containing an alkaline earth metal, a carbonic acidsource and the organic compound are subjected to a hydrothermalsynthesis.

Also, with the particles of the present invention, it is preferable thatthe carbonic acid source is formic acid and/or urea.

Also, with the particles of the present invention, it is preferable thata metal hydroxide containing an alkaline earth metal, a metal complexand the organic compound are subjected to a hydrothermal synthesis.

Also, with the particles of the present invention, it is preferable thatthe hydrothermal synthesis is performed in the presence of a pHadjusting agent.

Also, it is preferable that the particles of the present invention areobtained by subjecting an inorganic compound for forming inorganicparticles to a high temperature treatment in an organic compoundcontaining the organic group.

Also, it is preferable that the particles of the present invention aresubjected to wet classification using the solvent.

A particle dispersion according to the present invention contains asolvent and particles that are dispersed as primary particles in thesolvent, and the particles are organic-inorganic composite particleshaving an organic group on the surface of inorganic particles and havenegative birefringence.

A particle-dispersed resin composition according to the presentinvention contains a resin and particles that are dispersed as primaryparticles in the resin, and the particles are organic-inorganiccomposite particles having an organic group on the surface of inorganicparticles and have negative birefringence.

A resin molded article according to the present invention is formed of aparticle-dispersed resin composition containing a resin and particlesthat are dispersed as primary particles in the resin, and the particlesare organic-inorganic composite particles having an organic group on thesurface of inorganic particles and have negative birefringence.

Also, it is preferable that the resin molded article of the presentinvention is an optical film.

A second group of inventions for achieving the second object is asfollows.

Specifically, a particle-dispersed resin composition according to thepresent invention contains a resin and organic-inorganic compositeparticles having an organic group on the surface of inorganic particles,and the organic-inorganic composite particles have at least aconfiguration that does not allow the inorganic particles to contactwith each other by steric hindrance of the organic group and aredispersed as primary particles in the resin.

Also, with the particle-dispersed resin composition of the presentinvention, it is preferable that the resin has a functional group, andthe organic group and the functional group both have a hydrophilic groupor a hydrophobic group.

Also, with the particle-dispersed resin composition of the presentinvention, it is preferable that the resin contains a highly orientedresin.

Also, with the particle-dispersed resin composition of the presentinvention, it is preferable that the organic group contains a pluralityof homologous organic groups.

Also, with the particle-dispersed resin composition of the presentinvention, it is preferable that the organic group contains a pluralityof heterologous organic groups.

A particle-dispersed resin molded article according to the presentinvention is molded from a particle-dispersed resin compositioncontaining a resin and organic-inorganic composite particles having anorganic group on the surface of inorganic particles, and theorganic-inorganic composite particles have at least a configuration thatdoes not allow the inorganic particles to contact with each other bysteric hindrance of the organic group and are dispersed as primaryparticles in the resin.

A method for producing a particle-dispersed resin composition accordingto the present invention includes blending a resin and organic-inorganiccomposite particles having an organic group on the surface of inorganicparticles such that the organic-inorganic composite particles aredispersed as primary particles in the resin by steric hindrance of theorganic group.

With the method for producing a particle-dispersed resin composition ofthe present invention, it is preferable that the organic-inorganiccomposite particles are produced in a hot solvent. It is also preferablethat the organic-inorganic composite particles are produced in hot highpressure water.

A method for producing a particle-dispersed resin molded articleaccording to the present invention includes producing aparticle-dispersed resin molded article by molding a particle-dispersedresin composition obtained by blending a resin and organic-inorganiccomposite particles having an organic group on the surface of inorganicparticles such that the organic-inorganic composite particles aredispersed as primary particles in the resin by steric hindrance of theorganic group.

A third group of inventions for achieving the third object is asfollows.

Specifically, catalyst particles according to the present inventioncontain inorganic particles with a catalytic action and an organic groupthat binds to the surface of the inorganic particles, and have aconfiguration that does not allow the inorganic particles to contactwith each other by steric hindrance of the organic group.

It is preferable that the catalyst particles of the present inventionhave a catalytic action for a gas and/or a liquid.

Also, it is preferable that the catalyst particles of the presentinvention have a photocatalytic action for a gas and/or a liquid.

Also, it is preferable that the catalyst particles of the presentinvention are dispersed as primary particles in a solvent and/or aresin.

Also, it is preferable that the catalyst particles of the presentinvention contain a plurality of mutually different types of organicgroups.

Also, with the catalyst particles of the present invention, it ispreferable that the organic group is bound to the surface of theinorganic particles via a binding group, and the binding group containsa phosphoric acid group and/or a phosphoric acid ester group.

Also, with the catalyst particles of the present invention, it ispreferable that the inorganic particles contain an oxide.

Also, with the catalyst particles of the present invention, it ispreferable that the inorganic particles contain at least one oxideselected from the group consisting of TiO₂, WO₃ and SrTiO₃, and alsocontain at least one inorganic substance selected from the groupconsisting of Pt, Pd, Cu, CuO, RuO₂ and NiO.

Also, with the catalyst particles of the present invention, it ispreferable that the catalyst particles have an average maximum length of450 nm or less.

Also, it is preferable that the catalyst particles of the presentinvention are obtained by surface-treating an inorganic substance and/ora complex thereof with an organic compound containing the organic group.It is also preferable that the inorganic substance and/or the complexare surface-treated with the organic compound in hot high pressurewater, or that the inorganic substance and/or the complex aresurface-treated in the organic compound heated to a high temperature.

A catalyst solution according to the present invention contains asolvent and catalyst particles dispersed in the solvent, the catalystparticles contain inorganic particles with a catalytic action and anorganic group that binds to the surface of the inorganic particles, andthe catalyst particles have a configuration that does not allow theinorganic particles to contact with each other by steric hindrance ofthe organic group.

A catalyst composition according to the present invention contains aresin and catalyst particles dispersed in the resin, the catalystparticles contain inorganic particles with a catalytic action and anorganic group that binds to the surface of the inorganic particles, andthe catalyst particles have a configuration that does not allow theinorganic particles to contact with each other by steric hindrance ofthe organic group.

A catalyst molded article according to the present invention is formedof a catalyst composition containing a resin and catalyst particlesdispersed in the resin, the catalyst particles contain inorganicparticles with a catalytic action and an organic group that binds to thesurface of the inorganic particles, and the catalyst particles have aconfiguration that does not allow the inorganic particles to contactwith each other by steric hindrance of the organic group.

It is preferable that the catalyst molded article of the presentinvention is an optical film.

A fourth group of inventions for achieving the fourth object is asfollows.

Specifically, a resin molded article according to the present inventionhas micropores formed by removing organic-inorganic composite particlesfrom a particle-containing resin molded article containing a resin andthe organic-inorganic composite particles that contain inorganicparticles and an organic group that binds to the surface of theinorganic particles and have a configuration that does not allow theinorganic particles to contact with each other by steric hindrance ofthe organic group.

With the resin molded article of the present invention, it is preferablethat the organic-inorganic composite particles have an average maximumlength of 400 nm or less.

Also, with the resin molded article of the present invention, it ispreferable that in the particle-containing resin molded article, theorganic-inorganic composite particles are dispersed as primary particlesin the resin, or that the particle-containing resin molded article has aphase separated structure formed of a resin phase composed of the resinand a particle phase that is composed of the organic-inorganic compositeparticles and phase-separated from the resin phase, and the phaseseparated structure is a bicontinuous phase separated structure in whichthe particle phase is three-dimensionally continuous.

Also, with the resin molded article of the present invention, it ispreferable that the organic-inorganic composite particles partiallyremain, and the proportion of remaining organic-inorganic compositeparticles increases toward one side of the resin molded article.

Also, with the resin molded article of the present invention, it ispreferable that the organic group contains a plurality of mutuallydifferent organic groups.

A method for producing a resin molded article according to the presentinvention includes the steps of: preparing organic-inorganic compositeparticles that contain inorganic particles and an organic group thatbinds to the surface of the inorganic particles and have a configurationthat does not allow the inorganic particles to contact with each otherby steric hindrance of the organic group; blending the organic-inorganiccomposite particles with a resin so as to prepare a particle-containingresin composition and forming a particle-containing resin molded articlefrom the particle-containing resin composition; and forming microporesformed by removing the organic-inorganic composite particles from theparticle-containing resin molded article.

With the method for producing a resin molded article of the presentinvention, it is preferable that the step of preparing organic-inorganiccomposite particles involves surface-treating an inorganic material withan organic compound in hot high pressure water, or that the step ofpreparing organic-inorganic composite particles involvessurface-treating an inorganic material in a hot organic compound.

A fifth group of inventions for achieving the fifth object is asfollows.

Specifically, a titanium complex according to the present inventioncontains a titanium atom as a central atom and a hydroxycarboxylic acidhaving a total of 7 or more carbon atoms as a ligand.

With the present invention, it is preferable that the hydroxycarboxylicacid is a hydroxyalkanoic acid having a total of 7 or more carbon atoms.

Also, with the present invention, it is preferable that thehydroxyalkanoic acid is linear.

Also, with the present invention, it is preferable that thehydroxycarboxylic acid is a hydroxymonocarboxylic acid.

Also, with the present invention, it is preferable that thehydroxycarboxylic acid is a monohydroxycarboxylic acid.

Also, with the present invention, it is preferable that thehydroxycarboxylic acid has a total of 13 or fewer carbon atoms.

Also, with the present invention, it is preferable that thehydroxycarboxylic acid is 2-hydroxycarboxylic acid and/or3-hydroxycarboxylic acid.

Titanium oxide particles according to the present invention are obtainedby treating a titanium complex containing a titanium atom as a centralatom and a hydroxycarboxylic acid having a total of 7 or more carbonatoms as a ligand in hot high pressure water.

A method for producing titanium oxide particles according to the presentinvention includes treating a titanium complex containing a titaniumatom as a central atom and a hydroxycarboxylic acid having a total of 7or more carbon atoms as a ligand in hot high pressure water.

Effect of the Invention

The particles of the present invention can be dispersed as primaryparticles in a solvent and/or a resin, and therefore have excellentdispersibility in a solvent and/or a resin.

Accordingly, in the particle dispersion, particle-dispersed resincomposition and resin molded article of the present invention, theparticles are dispersed with good uniformity.

As a result, the resin molded article of the present invention canreliably have excellent optical characteristics.

The method for producing a particle-dispersed resin composition and themethod for producing a particle-dispersed resin molded article of thepresent invention enable organic-inorganic composite particles to bedispersed in a resin with ease and uniformity by using a simple methodin which the resin and the organic-inorganic composite particles areblended such that the organic-inorganic composite particles aredispersed as primary particles in the resin by steric hindrance of theorganic group.

Accordingly, because the organic-inorganic composite particles areuniformly dispersed in the resin, the particle-dispersed resincomposition and particle-dispersed resin molded article of the presentinvention have excellent clarity and are suitably used in variousindustrial applications including optical applications.

The catalyst particles of the present invention have a configurationthat does not allow the inorganic particles to contact with each otherby steric hindrance of the organic group, and therefore can be uniformlydispersed in a solvent and/or a resin.

Also, the catalyst solution of the present invention in which thecatalyst particles of the present invention are dispersed in a solventcan enhance clarity because the catalyst particles are uniformlydispersed.

Furthermore, with the catalyst composition of the present invention inwhich the catalyst particles of the present invention are dispersed in aresin, as well as the catalyst molded article of the present inventionformed of the catalyst composition, the inorganic particles cannoteasily come into direct contact with the resin due to the configurationbased on the steric hindrance of the organic group of the catalystparticles. Accordingly, the catalytic action for a gas or a liquid canbe exerted while degradation of the resin of the catalyst compositionand the catalyst molded article is suppressed.

As a result, the catalyst composition of the present invention and thecatalyst molded article of the present invention can exert variouscatalytic actions such as a detoxification action, a deodorizationaction, a disinfectant (or in other words, antimicrobial or germicidal)action, a dirt repellent action and a decomposition action while havingexcellent durability.

Also, the catalyst composition of the present invention and the catalystmolded article of the present invention can enhance clarity because thecatalyst particles are uniformly dispersed.

As a result, the catalyst molded article of the present invention can beused in various optical applications and various construction materialapplications.

The resin molded article of the present invention obtained by the methodfor producing a resin molded article of the present invention hasexcellent clarity and excellent mechanical strength.

Accordingly, the resin molded article of the present invention can beused in various industrial applications including optical applicationsas a resin molded article having excellent clarity and excellentreliability.

Also, the titanium complex of the present invention contains ahydroxycarboxylic acid having a total of 7 or more carbon atoms as aligand. For this reason, even when titanium oxide particles are preparedin hot high pressure water, decomposition of the ligand is suppressed,and thus coloring of the titanium oxide particles can be reduced.

Therefore, according to the present invention, it is possible to reducecoloring of titanium oxide particles while reducing the environmentalload.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an image-processed FE-SEM micrograph obtained in Example1-1;

FIG. 2 shows an image-processed FE-SEM micrograph obtained inComparative Example 1-2;

FIG. 3 shows an image-processed TEM micrograph obtained in Example 1-17;

FIG. 4 shows an image-processed FE-SEM micrograph obtained in Example1-29;

FIG. 5 shows an image-processed FE-SEM micrograph obtained inComparative Example 1-3;

FIG. 6 shows an image-processed FE-SEM micrograph obtained in Example1-47;

FIG. 7 shows an image-processed TEM micrograph obtained in Example 1-55;

FIG. 8 shows an image-processed TEM micrograph obtained in ComparativeExample 1-4;

FIG. 9 shows an image-processed FE-SEM micrograph obtained in Example1-56;

FIG. 10 shows a particle size distribution of particles in a particledispersion obtained in Preparation Example 1-1;

FIG. 11 shows an image-processed FE-SEM micrograph of a cross section ofa resin molded article in which particles obtained in Example 1-36 aredispersed;

FIG. 12 shows an image-processed FE-SEM micrograph of a cross section ofa resin molded article in which particles obtained in ComparativeExample 1-2 are dispersed;

FIG. 13 shows an image-processed FE-SEM micrograph of a cross section ofan optical film in which particles obtained in Example 1-36 aredispersed;

FIG. 14 shows an image-processed FE-SEM micrograph of a cross section ofan optical film in which particles obtained in Comparative Example 1-2are dispersed;

FIG. 15 shows an image-processed TEM micrograph of organic-inorganiccomposite particles obtained in Preparation Example 2-1;

FIG. 16 shows an image-processed TEM micrograph of a cut surface of afilm obtained in Example 2-1;

FIG. 17 shows an image-processed TEM micrograph of a cut surface of afilm obtained in Example 2-2;

FIG. 18 shows an image-processed TEM micrograph of a cut surface of afilm obtained in Example 2-3;

FIG. 19 shows an image-processed TEM micrograph of a cut surface of afilm obtained in Example 2-4;

FIG. 20 shows an image-processed TEM micrograph of a cut surface of afilm obtained in Example 2-7;

FIG. 21 shows an image-processed TEM micrograph of a cut surface of afilm obtained in Example 2-8;

FIG. 22 shows an image-processed TEM micrograph of a cut surface of afilm obtained in Example 2-11;

FIG. 23 shows an image-processed TEM micrograph of a cut surface of afilm obtained in Example 2-13;

FIG. 24 shows an image-processed TEM micrograph of a cut surface of afilm obtained in Example 2-14;

FIG. 25 shows UV-visible absorption spectra at the start of irradiationwith light and 30 minutes, 1 hour, 2 hours, 3 hours and 4 hours afterthe irradiation, obtained in Example 3-10;

FIG. 26 shows UV-visible absorption spectra at the start of irradiationwith light and 5 minutes, 10 minutes, 15 minutes, 30 minutes, 1 hour and2 hours after the irradiation, obtained in Example 3-66;

FIG. 27 shows an image-processed TEM micrograph of a porous filmobtained in Example 4-6;

FIG. 28 shows an image-processed TEM micrograph of a porous filmobtained in Example 4-7; and

FIG. 29 shows an image-processed TEM micrograph of a porous filmobtained in Example 4-13.

EMBODIMENT OF THE INVENTION

Hereinafter, first to fifth embodiments will be sequentially describedthat respectively correspond to the first to fifth groups of inventionsthat are included in the present invention and related to each other.

First Embodiment

Embodiment corresponding to the inventions of particles, a particledispersion, a particle-dispersed resin composition and a resin moldedarticle, which are included in the first group of inventions

The particles of the present invention are organic-inorganic compositeparticles that can be dispersed in a solvent and/or a resin as primaryparticles having an organic group on the surface of inorganic particles,and have negative birefringence.

Specifically, the primary particles are obtained as organic-inorganiccomposite particles obtained by surface-treating inorganic particleswith an organic compound.

That is, the inorganic compound (inorganic material) for forminginorganic particles has negative birefringence (minus birefringence) andcan be, for example, a carbonate containing an alkaline earth metaland/or a composite oxide containing an alkaline earth metal.

Examples of the alkaline earth metal include beryllium (Be), magnesium(Mg), calcium (Ca), strontium (Sr), barium (Ba), radium (Ra) and thelike. Magnesium and strontium are preferable. The alkaline earth metalscan be used singly or in a combination of two or more.

Specific examples of the carbonate containing an alkaline earth metalinclude beryllium carbonate, magnesium carbonate, calcium carbonate,strontium carbonate, barium carbonate, radium carbonate and the like.These carbonates can be used singly or in a combination of two or more.

Examples of the composite oxide containing an alkaline earth metalinclude alkaline earth metal salts of metal acids such as alkaline earthmetal titanates, alkaline earth metal ferrates, alkaline earth metalstannates and alkaline earth metal zirconates. The composite oxides canbe used singly or in a combination of two or more. Alkaline earth metaltitanates are preferable.

Examples of alkaline earth metal titanates include beryllium titanate(BeTiO₃), magnesium titanate (MgTiO₃), calcium titanate (CaTiO₃),strontium titanate (SrTiO₃), barium titanate (BaTiO₃), radium titanate(RaTiO₃) and the like. The alkaline earth metal titanates can be usedsingly or in a combination of two or more.

The organic compound is, for example, a hydrophobic organic compoundand/or a hydrophilic organic compound that imparts hydrophobicity and/orhydrophilicity to the surface of the inorganic particles. Specifically,the organic compound contains a binding group capable of binding to thesurface of the inorganic particles and a hydrophobic group and/or ahydrophilic group.

The binding group is selected as appropriate according to the type ofinorganic particles, and examples thereof include functional groups suchas carboxyl group, phosphoric acid group (—PO(OH)₂, phosphono group),amino group and sulfo group.

One or more of these binding groups may be contained in the organiccompound.

The hydrophobic group contained in the hydrophobic organic compound canbe, for example, a hydrocarbon group having 4 to 20 carbon atoms, andexamples thereof include alkyl group, alkenyl group, alkynyl group,cycloalkyl group, cycloalkenylalkylene group, aryl group, aralkyl groupand the like.

Examples of the alkyl group include linear or branched alkyl groupshaving 4 to 20 carbon atoms such as butyl, isobutyl, sec-butyl, t-butyl,pentyl, isopentyl, neopentyl, hexyl, heptyl, octyl, 2-ethylhexyl,3,3,5-trimethylhexyl, isooctyl, nonyl, isononyl, decyl, isodecyl,undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl,heptadecyl, octadecyl, nonadecyl and icosyl. A linear or branched alkylgroup having 6 to 18 carbon atoms is preferable.

Examples of the alkenyl group include alkenyl groups having 4 to 20carbon atoms such as hexenyl, octenyl, nonenyl, decenyl, undecenyl,dodecenyl, tetradecenyl, hexadecenyl, octadecenyl and icosenyl.

Examples of the alkynyl group include alkynyl groups having 4 to 20carbon atoms such as hexynyl, heptynyl, octynyl, decynyl, undecynyl,dodecynyl, tridecynyl, tetradecynyl, pentadecynyl, hexadecynyl,heptadecynyl and octadecynyl.

Examples of the cycloalkyl group include cycloalkyl groups having 4 to20 carbon atoms such as cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl,cyclodecyl, cycloundecyl and cyclododecyl.

Examples of the cycloalkenylalkylene group include norbornene decyl(norboneryl decyl, bicyclo[2.2.1]hepta-2-enyl-decyl) and the like.

Examples of the aryl group include aryl groups having 6 to 20 carbonatoms such as phenyl, xylyl, naphthyl and biphenyl.

Examples of the aralkyl group include aralkyl groups having 7 to 20carbon atoms such as benzyl, phenylethyl, phenylpropyl, diphenylmethyl,phenylbutyl, phenylpentyl, phenylhexyl and phenylheptyl.

The hydrophobic group is preferably an alkyl group, an alkenyl group, acycloalkyl group, a cycloalkenylalkylene group or an aralkyl group.

Specific examples of the hydrophobic organic compound include alkylgroup-containing compounds such as hexanoic acid,3,3,5-trimethylhexanoic acid, decanoic acid, decylamine, lauric acid,decylphosphonic acid, trioctylphosphinoxide; alkenyl group-containingcompounds such as 10-undecenoic acid, oleic acid; cycloalkylgroup-containing compounds such as cyclohexanepentanoic acid(cyclohexylpentanoic acid), cyclopentanedecanoic acid;cycloalkenylalkylene group-containing compounds such as norbornenedecanoic acid; aralkyl group-containing compounds such as6-phenylhexanoic acid, and the like.

The hydrophilic group contained in the hydrophilic organic compound canbe a hydroxyl group, a carbonyl groups or the like. One or more of thehydrophilic groups may be contained in the hydrophilic organic compound.

Specific examples of the hydrophilic organic compound include hydroxylgroup-containing compounds (monohydroxycarboxylic acids or estersthereof) such as ethyl 6-hydroxyhexanoate, 4-hydroxyphenylacetic acidand 3-(4-hydroxyphenyl)propionic acid; carbonyl group-containingcompounds (or in other words, monocarbonylcarboxylic acids) such as4-oxovaleric acid; and the like.

The hydrophobic group and/or the hydrophilic group serve as the organicgroup that is present on the surface of the inorganic particles of theorganic-inorganic composite particles.

The particles of the present invention can be obtained by subjecting theinorganic compound and the organic compound to a reaction treatment,preferably, a high temperature treatment.

Specifically, the particles of the present invention can be obtained bysubjecting the inorganic compound and the organic compound to a hightemperature treatment in water under high pressure (hydrothermalsynthesis: hydrothermal reaction) or by subjecting the inorganiccompound to a high temperature treatment in the organic compound (hightemperature treatment in the organic compound). In short, the particlesof the present invention can be obtained by surface-treating the surfaceof inorganic particles formed by the inorganic compound with the organicgroup.

In the hydrothermal synthesis, for example, the inorganic compound andthe organic compound are reacted under high-temperature andhigh-pressure conditions in the presence of water (first hydrothermalsynthesis).

Specifically, first, a reaction system is prepared underhigh-temperature and high-pressure conditions by placing the inorganiccompound, the organic compound and water in a pressure-resistantairtight container and heating them.

The proportions of respective components per 100 parts by weight of theinorganic compound are as follows: the proportion of the organiccompound is, for example, 5 to 160 parts by weight and preferably 10 to110 parts by weight; and the proportion of water is, for example, 200 to1000 parts by weight and preferably 400 to 700 parts by weight.

If the proportion of the organic compound is below the above range, thedegree of progress of the surface modification reaction will be small,which may result in poor dispersibility in a solvent and/or a resin. If,on the other hand, the proportion of the organic compound exceeds theabove range, the surface modification reaction will proceedsufficiently, but due to the excessive use of organic compound, the costmay increase.

If the proportion of water is below the above range, although thereaction will proceed, coarse particles (for example, with a maximumlength of approximately 0.2 to 0.8 mm) which may be unsuitable foroptical applications will be obtained.

If, on the other hand, the proportion of water exceeds the above range,the concentration of the inorganic compound will be excessively high,and the intended particles may not be produced.

The density of the organic compound is usually 0.8 to 1.1 g/mL, and thusthe proportion of the organic compound in terms of volume is, forexample, 10 to 150 mL and preferably 20 to 100 mL per 100 g of theinorganic compound.

Also, the number of moles of the organic compound can be, for example,0.01 to 1000 mol and preferably 0.1 to 10 mol per mol of metal containedin the inorganic compound.

Also, the density of water is usually approximately 1 g/mL, and thus theproportion of water in terms of volume is, for example, 200 to 1000 mLand preferably 400 to 700 mL per 100 g of the inorganic compound.

If the proportions of the organic compound and water fall within theabove ranges, the surface of inorganic particles can be reliablysurface-treated.

Specific reaction conditions for the hydrothermal reaction are asfollows. The heating temperature is, for example, 100 to 500° C. andpreferably 200 to 400° C.

If the heating temperature is below the above range, the hydrothermalreaction will not proceed sufficiently, as a result of which theinorganic compound may remain. If, on the other hand, the heatingtemperature exceeds the above range, although the hydrothermal reactionwill proceed, an excessive amount of heat will be generated, and thusthe cost and the environmental load may increase.

The pressure is, for example, 10 to 50 MPa, and preferably 20 to 40 MPa.

If the pressure is below the above range, the hydrothermal reaction willnot proceed sufficiently, as a result of which the inorganic compoundmay remain. If, on the other hand, the pressure falls within the aboverange, the hydrothermal reaction will proceed and the level of safetycan be enhanced.

The reaction time is, for example, 1 to 200 minutes and preferably 3 to150 minutes.

If the reaction time is below the above range, the hydrothermal reactionwill not proceed sufficiently, as a result of which the inorganiccompound may remain. If, on the other hand, the reaction time exceedsthe above range, although the hydrothermal reaction will proceed, theparticle growth will also proceed to give coarse particles which may beunsuitable for optical applications. Also, due to the long reactiontime, the cost may increase.

After the hydrothermal reaction, the airtight container is cooled, andthen, for example, a precipitate precipitated on the bottom wall of theairtight container or a deposit adhering to the inner wall of theairtight container is recovered.

The precipitate is obtained by, for example, sedimentation separation inwhich the reaction product is settled by gravity or a centrifugal field.Preferably, the precipitate is obtained as a precipitate of the reactionproduct by centrifugal sedimentation (centrifugal separation) in whichthe reaction product is settled by a centrifugal field.

The deposit is recovered by, for example, a scraper (spatula) or thelike.

The reaction product can also be recovered (separated) by adding asolvent to wash away an unreacted organic compound (or in other words,dissolving the organic compound in the solvent) and thereafter removingthe solvent.

As the solvent, for example, an alcohol such as methanol, ethanol,propanol or isopropanol or a ketone such as acetone or methyl ethylketone can be used, and an alcohol is preferably used.

The washed reaction product is separated from the solvent (supernatantliquid) by, for example, filtration, decantation or the like, andrecovered.

In this manner, the particles are obtained.

The particles of the present invention can also be obtained bysubjecting a metal hydroxide containing an alkaline earth metal, acarbonic acid source and an organic compound to a hydrothermal synthesis(second hydrothermal synthesis).

Examples of the alkaline earth metal contained in the metal hydroxidecontaining an alkaline earth metal include the same alkaline earthmetals as those of the carbonates listed above.

Specific examples of the metal hydroxide include beryllium hydroxide,magnesium hydroxide, calcium hydroxide, strontium hydroxide, bariumhydroxide, radium hydroxide and the like.

The carbonic acid source is, for example, formic acid and/or urea.

Examples of the organic compound include the same organic compounds asthose used in the first hydrothermal synthesis described above.

In the second hydrothermal synthesis, the metal hydroxide, the carbonicacid source and the organic compound are reacted under high-temperatureand high-pressure conditions in the presence of water.

The proportions of respective components per 100 parts by weight of themetal hydroxide are as follows: the proportion of the carbonic acidsource is, for example, 5 to 140 parts by weight and preferably 10 to 70parts by weight; the proportion of the organic compound is, for example,4 to 550 parts by weight and preferably 15 to 330 parts by weight; andthe proportion of water is, for example, 150 to 2500 parts by weight andpreferably 300 to 500 parts by weight.

If the proportion of the carbonic acid source is below the above range,the concentration of the metal hydroxide will be excessively low, andthe particles may not be obtained. If, on the other hand, the proportionof the carbonic acid source exceeds the above range, although thereaction will proceed, coarse particles which may be unsuitable foroptical applications will be obtained.

If the proportion of the organic compound is below the above range, thesurface modification reaction will not proceed sufficiently, which mayresult in poor dispersibility in a solvent and/or a resin. If, on theother hand, the proportion of the organic compound exceeds the aboverange, the surface modification reaction will proceed sufficiently, butdue to the excessive use of organic compound, the cost may increase.

If the proportion of water is below the above range, although thereaction will proceed, coarse particles which may be unsuitable foroptical applications will be obtained. If, on the other hand, theproportion of water exceeds the above range, the concentration of themetal hydroxide will be excessively high, and the intended particles maynot be produced.

The density of the carbonic acid source is usually 1.1 to 1.4 g/mL, andthus the proportion of the carbonic acid source in terms of volume is,for example, 5 to 100 mL and preferably 10 to 50 mL per 100 g of themetal hydroxide. Also, the number of moles of the carbonic acid sourcemay be, for example, 0.4 to 100 mol, preferably 1.01 to 10.0 mol andmore preferably 1.05 to 1.30 mol per mol of the metal hydroxide.

Also, the proportion of the organic compound in terms of volume is, forexample, 5 to 500 mL, and preferably 20 to 300 mL per 100 g of the metalhydroxide, and the number of moles of the organic compound may be, forexample, 0.01 to 10000 mol and preferably 0.1 to 10 mol per mol of themetal hydroxide.

Also, the proportion of water in terms of volume is, for example, 150 to2500 mL and preferably 300 to 500 mL per 100 g of the metal hydroxide.

If the proportions of the organic compound and water fall within theabove ranges, the surface of inorganic particles can be reliablysurface-treated.

The reaction conditions for the second hydrothermal synthesis are thesame as those for the first hydrothermal synthesis described above.

Furthermore, in the present invention, the particles of the presentinvention can also be obtained by subjecting a metal hydroxidecontaining an alkaline earth metal, a metal complex and an organiccompound to a hydrothermal synthesis (third hydrothermal synthesis).

Examples of the metal hydroxide containing an alkaline earth metalinclude the same metal hydroxides containing an alkaline earth metal asthose used in the second hydrothermal synthesis described above.

The metal element contained in the metal complex is a metal element thatconstitutes a composite oxide with the alkaline earth metal contained inthe metal hydroxide, and examples thereof include elemental titanium,elemental iron, elemental tin, elemental zirconium and the like.Elemental titanium is preferable.

Examples of the ligand of the metal complex includemonohydroxycarboxylic acids such as 2-hydroxyoctanoic acid and the like.

Examples of the metal complex include 2-hydroxyoctanoic acid titanateand the like. The metal complex can be obtained by preparation from themetal element and the ligand.

Examples of the organic compound include the same organic compounds asthose used in the first hydrothermal synthesis described above.

In the third hydrothermal synthesis, the metal hydroxide, the metalcomplex and the organic compound are reacted under high-temperature andhigh-pressure conditions in the presence of water.

The proportions of respective components per 100 parts by weight of themetal complex are as follows: the proportion of the metal hydroxide is,for example, 1 to 50 parts by weight and preferably 5 to 30 parts byweight; the proportion of the organic compound is, for example, 4 to 550parts by weight and preferably 15 to 330 parts by weight; and theproportion of water is, for example, 200 to 1000 parts by weight andpreferably 300 to 700 parts by weight.

If the proportion of the metal hydroxide is below the above range, theconcentration of the metal hydroxide will be excessively low, and theparticles may not be obtained. If, on the other hand, the proportion ofthe metal hydroxide exceeds the above range, although the surfacemodification reaction will proceed, coarse particles which may beunsuitable for optical applications will be obtained.

If the proportion of the organic compound is below the above range, thesurface modification reaction will not proceed sufficiently, which mayresult in poor dispersibility in a solvent and/or a resin. If, on theother hand, the proportion of the organic compound exceeds the aboverange, the surface modification reaction will proceed sufficiently, butdue to the excessive use of organic compound, the cost may increase.

If the proportion of water is below the above range, although thereaction will proceed, coarse particles which may be unsuitable foroptical applications will be obtained. If, on the other hand, theproportion of water exceeds the above range, the concentration of themetal hydroxide will be excessively high, and the intended particles maynot be produced.

The proportion of the organic compound in terms of volume is, forexample, 5 to 500 mL and preferably 20 to 300 mL per 100 g of the metalcomplex, and the number of moles of the organic compound may be 0.01 to1000 per mol of the organic compound.

The proportion of water in terms of volume is, for example, 200 to 1000mL and preferably 300 to 700 mL per 100 g of the metal complex.

If the proportions of the organic compound and water fall within theabove ranges, the surface of inorganic particles can be reliablysurface-treated.

The reaction conditions for the third hydrothermal synthesis are thesame as those for the first hydrothermal synthesis described above.

Furthermore, the above hydrothermal syntheses (first, second and thirdhydrothermal syntheses) may also be carried out in the presence of a pHadjusting agent.

Preferably, the second hydrothermal synthesis is carried out in thepresence of a pH adjusting agent.

The pH adjusting agent can be an alkali or acid.

Examples of the alkali include inorganic alkalis such as potassiumhydroxide and sodium hydroxide; organic alkalis such as ammonia; and thelike. Examples of the acid include inorganic acids such as sulfuricacid, nitric acid and hydrochloric acid; organic acids such as formicacid and acetic acid; and the like.

Preferably, an alkali is used.

The pH of the reaction system is set to, for example, 8 to 12 by usingthe pH adjusting agent.

It is thereby possible to set the average particle size of the resultingparticles in the desired range, more specifically, to a smaller value.Accordingly, the particles having a small average particle size (orlengthwise length LL and sideways length SL, which will be describedlater) can be suitably used in optical applications.

Examples of the inorganic compound subjected to the high temperaturetreatment in the organic compound include the same inorganic compoundsas those listed above.

In the high temperature treatment in the organic compound, the inorganiccompound and the organic compound are blended and heated under, forexample, normal atmospheric pressure conditions.

The proportion of the organic compound is, for example, 10 to 10000parts by weight and preferably 100 to 1000 parts by weight per 100 partsby weight of the inorganic compound. The proportion of the organiccompound in terms of volume is, for example, 10 to 10000 mL andpreferably 100 to 1000 mL per 100 g of the inorganic compound.

The heating temperature is, for example, a temperature above 100° C.,preferably 125° C. or higher and more preferably 150° C. or higher, andusually for example, 300° C. or lower, and preferably 275° C. or lower.

The heating time is, for example, 1 to 60 minutes and preferably 3 to 30minutes.

The particles (primary particles) thus obtained are mostly acicular,with a lengthwise length (maximum length) LL of, for example, 200 μm orless, preferably 5 nm to 200 μm, more preferably 10 nm to 50 μm and evenmore preferably 40 nm to 10 μm and a sideways length (minimum length) SLof, for example, 1 nm to 20 μm, preferably 3 nm to 10 μm and morepreferably 5 nm to 5 μm.

In particular, the particles (primary particles) obtained byhydrothermal synthesis in the presence of a pH adjusting agent have alengthwise length LL of, for example, 1 nm to 20 μm and preferably 10 nmto 10 μm and a sideways length SL of, for example, 0.5 nm to 2 μm andpreferably 1 nm to 1 μm.

If the lengthwise length LL is below the above range, the particles willbe too small, which may result in poor physical strength. If, on theother hand, the lengthwise length LL exceeds the above range, goodoptical characteristics will be obtained, but the particles may becrushed when mixed with a resin or the like.

If the sideways length SL is below the above range, the particles willbe too small, which may result in poor physical strength. If, on theother hand, the sideways length SL exceeds the above range, a sufficientaspect ratio may not be obtained.

The particles have an aspect ratio of, for example, 1000 or less,specifically, 1 to 1000, preferably 3 to 100 and more preferably 5 to30.

If the aspect ratio is below the above range, poor opticalcharacteristics will be obtained. If, on the other hand, the aspectratio exceeds the above range, good optical characteristics will beobtained, but the particles may be crushed when mixed with a resin orthe like.

The particles thus obtained are unlikely to coagulate in a dry state,and even if the particles appear coagulated in a dry state, thecoagulation (formation of secondary particles) will be reliablyprevented in a particle dispersion and/or a particle-dispersed resincomposition, which will be described next, and therefore the particlesare dispersed as primary particles substantially uniformly in a solventand/or a resin.

The particles obtained in the above-described manner can be subjected towet classification.

Specifically, a solvent is added to the particles, and the resultingmixture is stirred and allowed to stand still, and thereafter separatedinto a supernatant and a precipitate. As the solvent, the same solventsas those listed above can be used.

After that, the supernatant is recovered to give particles having asmall particle size.

With the wet classification, the lengthwise length LL of the resultingparticles can be adjusted to, for example, 10 nm to 400 nm andpreferably 20 nm to 200 nm, and the sideways length SL can be adjustedto, for example, 1 nm to 100 nm and preferably 5 nm to 50 nm.

If the lengthwise length LL is below the above range, the particle willbe too small, which may result in poor physical strength. If, on theother hand, the lengthwise length LL exceeds the above range, goodoptical characteristics will be obtained, but the particles may becrushed when mixed with a resin or the like.

If the sideways length SL is below the above range, the particles willbe too small, which may result in poor physical strength. If, on theother hand, the sideways length SL exceeds the above range, a sufficientaspect ratio may not be obtained.

There is no particular limitation on the solvent for dispersing theparticles obtained above. Examples thereof include the solvents used inwashing described above, and other examples include halogenatedhydrocarbons such as chloroform, dichloromethane, 1,1,1-trichloroethane,chlorobenzene and dichlorobenzene; alkanes such as pentane, hexane andheptane; cycloalkanes such as cyclopentane and cyclohexane; esters suchas ethyl acetate; polyols such as ethylene glycol and glycerin; aromatichydrocarbons such as benzene, toluene and xylene; ethers such astetrahydrofuran; nitrogen-containing compounds such asN-methylpyrrolidone, pyridine, acetonitrile and dimethylformamide; andthe like.

These solvents can be used singly or in a combination of two or more.

The proportion of the solvent is not particularly limited, and theconcentration of the particles in the particle dispersion is adjustedto, for example, 0.1 to 70 wt % and preferably 1 to 50 wt %.

If the concentration of the particles in the particle dispersion isbelow the above range, the particle dispersion will be too dilute, andthus sufficient optical characteristics may not be obtained when mixedwith a resin or the like. If, on the other hand, the concentration ofthe particles in the particle dispersion exceeds the above range, thedispersibility will be low.

In order to disperse the particles in the solvent, the particles and thesolvent are blended, and the resulting mixture is stirred.

As a result, in the particle dispersion, the particles are uniformlydispersed as primary particles in the solvent, or in other words,without coagulation of the particles.

There is no particular limitation on the resin for dispersing theparticles, and examples thereof include thermosetting resins,thermoplastic resins and the like.

Examples of thermosetting resins include epoxy resin, polyimide resin(thermosetting polyimide resin), phenol resin, urea resin, melamineresin, diallyl phthalate resin, silicone resin, urethane resin(thermosetting urethane resin) and the like.

Examples of thermoplastic resins include polyolefin (for example,polyethylene, polypropylene, ethylene-propylene copolymer and the like),acrylic resin (for example, polymethyl methacrylate and the like),polyvinyl acetate, ethylene-vinylacetate copolymer (EVA), polyvinylchloride, polystyrene, polyacrylonitrile, polyamide (PA; nylon),polycarbonate, polyacetal, polyester (for example, polyarylate,polyethylene terephthalate (PET) and the like), polyphenylene oxide,polyphenylene sulfide, polysulfone, polyether sulfone, polyether etherketone (PEEK), polyallylsulfone, thermoplastic polyimide resin,thermoplastic urethane resin, polyaminobismaleimide, polyamideimide,polyetherimide, bismaleimidetriazine resin, polymethylpentene, fluorineresin, liquid crystal polymer, olefin-vinyl alcohol copolymer, ionomer,polyarylate, acrylonitrile-ethylene-styrene copolymer (AES),acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-styrenecopolymer (AS) and the like.

These resins can be used singly or in a combination of two or more.

Among the resins, a thermoplastic resin is preferable, andpolyetherimide and polyester are more preferable.

The resin (specifically, thermoplastic resin) has a melting temperatureof, for example, 200 to 300° C. and a softening temperature of, forexample, 150 to 280° C.

In order to disperse the particles in the resin, for example, at leastthe particles and the resin are blended, and the resulting mixture isstirred.

Preferably, the particles, the solvent and the resin are blended, theresulting mixture is stirred to prepare a particle-dispersed resinsolution, and thereafter the solvent in the particle-dispersed resinsolution is removed. Blending a solvent allows the particles to be moreuniformly dispersed in the resin.

Specifically, a resin solution and/or a resin dispersion that has beendissolved and/or dispersed in a solvent are/is blended with the particledispersion.

As the solvent used in preparation of the resin solution and/or theresin dispersion, the same solvents as those listed above can be used.The proportion of the solvent is adjusted to, for example, 40 to 2000parts by weight and preferably 50 to 1000 parts by weight per 100 partsby weight of the resin solution and/or the resin dispersion.

If the proportion of the solvent is below the above range, the resinsolution or the resin dispersion will be too viscous, making itsapplication difficult, and also the dispersibility of the particles willbe low. If, on the other hand, the proportion of the solvent exceeds theabove range, the resin solution or the resin dispersion will be toodilute and the viscosity is too small, making it difficult to apply theresin solution or the resin dispersion so as to be thick.

The proportion between the resin solution and/or the resin dispersionand the particle dispersion is adjusted such that the proportion of theparticles is, for example, 0.1 to 240 parts by weight and preferably 5to 100 parts by weight per 100 parts by weight of the resin (solidscontent). In other words, the concentration of the particles in theparticle-dispersed resin composition is adjusted to 0.1 to 70 wt % andpreferably 1 to 50 wt %.

If the proportion of the particles is below the above range, theparticle-dispersed resin composition will be too dilute, and thussufficient optical characteristics may not be obtained in theparticle-dispersed resin composition. If, on the other hand, theproportion of the particles exceeds the above range, the dispersibilityof the particles will be low.

After that, the particle-dispersed resin composition is dried byapplication of heat at, for example, 40 to 60° C. to remove the solvent,and thereby a particle-dispersed resin composition is obtained.

After that, the particle-dispersed resin composition is injected into ametal mold or the like and then subjected to, for example, heat moldingsuch as heat pressing, whereby the resin molded article of the presentinvention can be obtained.

As heat pressing, for example, vacuum pressing is used. The conditionsare as follows: the temperature is greater than or equal to the meltingtemperature or softening temperature of the resin, specifically, 100 to300° C. and preferably 150 to 250° C.; and the pressing pressure is, forexample, 20 to 1000 MPa and preferably 40 to 80 MPa.

If the heating temperature is below the above range, it may not bepossible to soften the resin. If, on the other hand, the heatingtemperature exceeds the above range, the resin may be thermallydecomposed, and also the cost may increase due to an excessive amount ofheat generated.

If the pressing pressure is below the above range, the resin may not besufficiently deformed (molded). If, on the other hand, the pressingpressure exceeds the above range, the resin can be sufficiently molded,but the pressing pressure will be excessively high, which may increasethe cost.

The resin molded article of the present invention can be obtained by(application method) applying the particle-dispersed resin solution ontoa support plate by using, for example, an application method such asspin coating or roll coating, subsequently removing the solvent at thesame temperature as described above, and then if necessary curing theresultant by application of heat so as to form a coating that is made ofthe particle-dispersed resin composition, and if necessary furtherdrying the coating.

Furthermore, the resin molded article of the present invention can alsobe obtained by an extrusion method in which the particle-dispersed resincomposition is extruded by an extruding machine or the like.

As a result, in the resin molded article, the particles are uniformlydispersed as primary particles in the resin, or in other words, withoutcoagulation of the particles.

The resin molded article of the present invention has variousapplications including, for example, optical applications, electronicand electrical applications and mechanical applications. In the case ofelectronic and electrical applications, for example, the resin moldedarticle of the present invention is used as a flexible substrate or thelike.

Preferably, the resin molded article of the present invention is used inoptical applications, specifically, as an optical fiber, an opticaldisc, a light guide plate, an optical film or the like.

The thickness of the optical film is, for example, 1 to 100 μm andpreferably 5 to 50 μm.

If the thickness of the optical film is below the above range,sufficient optical characteristics may not be obtained. If, on the otherhand, the thickness of the optical film exceeds the above range,although sufficient optical characteristics can be obtained, it may bedifficult to form a uniform film and the cost may increase.

In the case where the resin molded article is used as an optical film,the resin molded article is formed into a film suitable for opticalapplications by the application method, or in other words, an opticalfilm is obtained.

The particles of the present invention can be dispersed as primaryparticles in a solvent and/or a resin, and therefore have excellentdispersibility in a solvent and/or a resin.

Accordingly, in the particle dispersion and the particle-dispersed resincomposition of the present invention, the particles are dispersed withgood uniformity.

Moreover, the particles of the present invention have negativebirefringence.

Accordingly, the resin molded article of the present invention canreliably have excellent optical characteristics and thus is useful as anoptical member, in particular, as an optical film.

More specifically, the particles of the present invention have aparticle size (lengthwise length LL and sideways length SL) that issmaller than the wavelength of light (for example, 380 to 800 nm in thecase of visible light) and are dispersed in the resin molded article ofthe present invention, and therefore negative birefringence can beimparted to the optical film with excellent reliability.

For this reason, the optical film of the present invention can besuitably used in phase difference plates or polarizing plates for plasmadisplay panels or liquid crystal televisions, or the like.

Second Embodiment

Embodiment corresponding to the inventions of a particle-dispersed resincomposition, a particle-dispersed resin molded article and producingmethods therefor, which are included in the second group of inventions

The particle-dispersed resin composition of the present inventioncontains a resin and organic-inorganic composite particles.

Examples of the resin include thermosetting resins, thermoplastic resinsand the like.

Examples of thermosetting resins include polycarbonate resin, epoxyresin, thermosetting polyimide resin (including thermosettingfluorine-based polyimide resin), phenol resin, urea resin, melamineresin, diallyl phthalate resin, silicone resin, thermosetting urethaneresin and the like.

Examples of thermoplastic resins include olefin resin, acrylic resin,polystyrene resin, polyester resin, polyacrylonitrile resin, maleimideresin, polyvinyl acetate resin, ethylene-vinylacetate copolymer,polyvinyl alcohol resin, polyamide resin, polyvinyl chloride resin,polyacetal resin, polyphenylene oxide resin, polyphenylene sulfideresin, polysulfone resin, polyether sulfone resin, polyether etherketone resin, polyallylsulfone resin, thermoplastic polyimide resin(including thermoplastic fluorine-based polyimide resin), thermoplasticurethane resin, polyetherimide resin, polymethylpentene resin, celluloseresin, liquid crystal polymer, ionomer and the like.

These resins can be used singly or in a combination of two or more.

In the case where excellent mechanical strength needs to be imparted tothe particle-dispersed resin molded article molded from aparticle-dispersed resin composition, the resin is preferably a highlyoriented resin having high orientation, and specific examples thereofinclude olefin resin, acrylic resin, polystyrene resin, polyester resin,polyvinyl alcohol resin, thermoplastic polyimide resin, polyetherimideresin, liquid crystal polymer and the like.

Examples of the olefin resin include cyclic olefin resin, chain olefinresin and the like. Cyclic olefin resin is preferable.

Examples of the cyclic olefin resin include polynorbornene,ethylene-norbornene copolymers, and derivative thereof.

Examples of the chain olefin resin include polyethylene, polypropylene,ethylene-propylene copolymer and the like.

Examples of the acrylic resin include polymethyl methacrylate and thelike.

Examples of the polyester resin include polyarylate, polyethyleneterephthalate, polyethylene naphthalate and the like.

The polyvinyl alcohol resin is obtained by, for example, complete orpartial saponification of polyvinyl acetate resin obtained bypolymerizing vinyl monomers containing vinyl acetate as a primarycomponent by an appropriate method. The saponification degree ofpolyvinyl alcohol resin is, for example, 70 to 99.99 mol % andpreferably 70 to 99.9 mol %.

The resin preferably has a functional group. Examples of the functionalgroup include hydrophilic groups such as carboxyl group and hydroxylgroup; hydrophobic groups such as hydrocarbon group; and the like.

The organic-inorganic composite particles are particles that can bedispersed as primary particles in a solvent (described later) and/or aresin and that have an organic group on the surface of the inorganicparticles. Specifically, the organic-inorganic composite particles areobtained by surface-treating inorganic particles with an organiccompound. The organic-inorganic composite particles can be used singlyor in a combination of two or more.

The inorganic substance for forming inorganic particles can be a metalcomposed of a metal element such as a main group element or a transitionelement, a nonmetal composed of a nonmetal element such as boron orsilicon, an inorganic compound containing a metal element and/or anonmetal, or the like.

Examples of the metal element and the nonmetal element include elementsthat are located on the left side and the lower side of a border linethat is assumed to pass through boron (B) of the IIIB group, silicon(Si) of the IVB group, arsenic (As) of the VB group, tellurium (Te) ofthe VIB group and astatine (At) of the VIIB group on the long-formperiodic table (IUPAC, 1989), as well as the elements that are locatedon the border line. Specific examples thereof include the group IIIAelements such as Sc and Y; the group IVA elements such as Ti, Zr, andHf; the group VA elements such as V, Nb, and Ta; the group VIA elementssuch as Cr, Mo, and W; the group VIIA elements such as Mn and Re; thegroup VIIIA elements such as Fe, Co, Ni, Ru, Rh, Pd, Os, Ir, and Pt; thegroup IB elements such as Cu, Ag, and Au; the group IIB elements such asZn, Cd, and Hg; the group IIIB elements such as B, Al, Ga, In, and Tl;the group IVB elements such as Si, Ge, Sn, and Pb; the group VB elementssuch as As, Sb, and Bi; the group VIB elements such as Te and Po; thelanthanide series elements such as La, Ce, Pr, and Nd; the actiniumseries elements such as Ac, Th, and U; and the like.

The inorganic compound can be, for example, a hydrogen compound, ahydroxide, a nitride, a halide, an oxide, a carbonate, a sulfate, anitrate, a metal complex, a sulfide, a carbide, a phosphorus compound,or the like. The inorganic compound may be a composite compound such as,for example, an oxynitride or a composite oxide.

The inorganic substance is preferably an inorganic compound, and morepreferable examples include an oxide, a composite oxide, a carbonate, asulfate and the like.

Examples of the oxide include metal oxides, and preferable examplesinclude titanium oxide (titanium dioxide, titanium oxide (IV), titania:TiO₂), cerium oxide (cerium dioxide, cerium oxide (IV), ceria: CeO₂) andthe like.

The oxides can be used singly or in a combination of two or more.

The composite oxide is a compound consisting of oxygen and a pluralityof elements, and the plurality of elements may be a combination of atleast two elements selected from the elements other than oxygencontained in the oxides listed above, the group I elements, and thegroup II elements.

Examples of the group I elements include alkali metals such as Li, Na,K, Rb, and Cs. Examples of the group II elements include the samealkaline earth metals as those listed in the first embodiment.

Preferable examples of the combination of a plurality of elementsinclude combinations that contain at least a group II element such as acombination of a group II element and a group IVB element, a combinationof a group II element and a group VIIIB element, and a combination of agroup II element and a group IVA element.

Examples of the composite oxide containing at least a group II elementinclude alkaline earth metal titanates, alkaline earth metal zirconates,alkaline earth metal ferrates, alkaline earth metal stannates, and thelike.

Preferable composite oxides are alkaline earth metal titanates.

Examples of alkaline earth metal titanates include the same alkalineearth metal titanates as those listed in the first embodiment.

The composite oxides can be used singly or in a combination of two ormore.

In the carbonate, the element that combines with carbonic acid can be,for example, an alkali metal, an alkaline earth metal or the like. Thealkali metal and the alkaline earth metal can be the same alkali metalsand alkaline earth metals as those listed above.

The element that combines with carbonic acid is preferably an alkalineearth metal.

Specifically, the carbonate is preferably a carbonate containing analkaline earth metal, and examples of such a carbonate include the samecarbonates as those listed in the first embodiment. These carbonates canbe used singly or in a combination of two or more.

The sulfate is a compound consisting of a sulfate ion (SO₄ ²⁻) and ametal cation (more specifically, a compound formed by substitution ofthe hydrogen atoms of sulfuric acid (H₂SO₄) with a metal), and the metalcontained in the sulfate can be, for example, an alkali metal, analkaline earth metal or the like. The alkali metal and the alkalineearth metal can be the same alkali metals and alkaline earth metals asthose listed above.

The metal is preferably an alkaline earth metal.

Specifically, preferable sulfates are sulfates containing an alkalineearth metal, and examples of such sulfates include beryllium sulfate,magnesium sulfate, calcium sulfate, strontium sulfate, barium sulfate,radium sulfate and the like. Barium sulfate is preferable.

These sulfates can be used singly or in a combination of two or more.

The organic compound is, for example, an organic group-introducingcompound that introduces (disposes) an organic group on the surface ofinorganic particles. Specifically, the organic compound contains abinding group capable of binding to the surface of inorganic particlesand an organic group.

The binding group may be selected as appropriate according to the typeof inorganic particles, and examples thereof include functional groupssuch as carboxyl group, phosphoric acid group (—PO(OH)₂, phosphonogroup), amino group, sulfo group, hydroxyl group, thiol group, epoxygroup, isocyanate group (cyano group), nitro group, azo group, silyloxygroup, imino group, aldehyde group (acyl group), nitrile group, vinylgroup (polymerizable group), and the like. Preferable examples includecarboxyl group, phosphoric acid group, amino group, sulfo group,hydroxyl group, thiol group, epoxy group, azo group, vinyl group, andthe like. More preferable examples include carboxyl group and phosphoricacid group.

The carboxyl group includes a carboxylic acid ester group (carboxy estergroup).

The phosphoric acid group includes a phosphoric acid ester group(phosphonate group).

One or more of these binding groups are contained in the organiccompound. Specifically, the binding group is bound to a terminal or aside chain of the organic group.

The binding group is selected as appropriate according to the type ofinorganic particles. Specifically, when the inorganic particles containcerium oxide, strontium carbonate and/or barium sulfate, for example, acarboxyl group is selected. When the inorganic particles containtitanium oxide, for example, a phosphoric acid group is selected.

The organic group includes, for example, a hydrocarbon group such as analiphatic group, an alicyclic group, an araliphatic group or an aromaticgroup, or the like.

The aliphatic group includes, for example, a saturated aliphatic group,an unsaturated aliphatic group and the like.

Examples of the saturated aliphatic group include alkyl groups having 1to 20 carbon atoms and the like.

Examples of the alkyl group include linear or branched alkyl groups(paraffin hydrocarbon groups) having 1 to 20 carbon atoms such asmethyl, ethyl, propyl, isopropyl, butyl, isobutyl, sec-butyl, t-butyl,pentyl, isopentyl, neopentyl, hexyl, heptyl, octyl, 2-ethylhexyl,3,3,5-trimethylhexyl, isooctyl, nonyl, isononyl, decyl, isodecyl,undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl,heptadecyl, octadecyl, nonadecyl and icosyl, and the like. A linear orbranched alkyl group having 4 to 18 carbon atoms is preferable.

Examples of the unsaturated aliphatic group include alkenyl groupshaving 2 to 20 carbon atoms, alkynyl groups having 2 to 20 carbon atoms,and the like.

Examples of the alkenyl group include alkenyl groups (olefin hydrocarbongroups) having 2 to 20 carbon atoms such as ethenyl, propenyl, butenyl,pentenyl, hexenyl, octenyl, nonenyl, decenyl, undecenyl, dodecenyl,tetradecenyl, hexadecenyl, octadecenyl (oleyl) and icosenyl.

Examples of the alkynyl group include alkynyl groups (acetylenehydrocarbon groups) having 2 to 20 carbon atoms such as ethynyl,propynyl, butynyl, pentynyl, hexynyl, heptynyl, octynyl, decynyl,undecynyl, dodecynyl, tridecynyl, tetradecynyl, pentadecynyl,hexadecynyl, heptadecynyl and octadecynyl.

Examples of the alicyclic group include cycloalkyl groups having 4 to 20carbon atoms, cycloalkenylalkylene groups having 7 to 20 carbon atoms,and the like.

Examples of the cycloalkyl group include cyclobutyl, cyclopentyl,cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl,cycloundecyl, cyclododecyl and the like.

Examples of the cycloalkenylalkylene group include norbornene decyl(norboneryl decyl, bicyclo[2.2.1]hept-2-enyl-decyl) and the like.

Examples of the araliphatic group include aralkyl groups having 7 to 20carbon atoms such as benzyl, phenylethyl, phenylpropyl, phenylbutyl,phenylpentyl, phenylhexyl, phenylheptyl and diphenylmethyl.

Examples of the aromatic group include aryl groups having 6 to 20 carbonatoms such as phenyl, xylyl, naphthyl and biphenyl.

The organic group is used as a hydrophobic group for impartinghydrophobicity to the surface of inorganic particles.

Accordingly, the organic compounds containing a hydrophobic groupdescribed above are used as hydrophobic organic compounds forhydrophobic treatment of inorganic particles.

Specific examples of such hydrophobic organic compounds in the casewhere the binding group is a carboxyl group include aliphaticgroup-containing carboxylic acids including saturated aliphaticgroup-containing carboxylic acids (saturated fatty acids) such ashexanoic acid and decanoic acid and unsaturated aliphaticgroup-containing carboxylic acids (unsaturated fatty acids) such asoleic acid, and the like. Other specific examples of hydrophobic organiccompounds in the case where the binding group is a carboxyl groupinclude alicyclic group-containing carboxylic acids (alicycliccarboxylic acids) such as cyclohexyl monocarboxylic acid, araliphaticgroup-containing carboxylic acids (araliphatic carboxylic acids) such as6-phenylhexanoic acid, aromatic group-containing carboxylic acids(aromatic carboxylic acids) such as benzoic acid and toluenecarboxylicacid, and the like.

Specific examples of hydrophobic organic compounds in the case where thebinding group is a phosphoric acid group (including phosphoric acidester group), aliphatic group-containing phosphate esters includingsaturated aliphatic group-containing phosphate esters such as ethyloctylphosphonate and ethyl decylphosphonate.

The organic compound can also be used as a hydrophilic organic compoundfor hydrophilic treatment of inorganic particles. In this case, theorganic group contained in the hydrophilic organic compound includes anyof the above hydrocarbon groups and a hydrophilic group that binds tothe hydrocarbon group.

That is, in the hydrophilic organic compound, the hydrophilic group isbound to a terminal (the terminal (the other terminal) opposite theterminal that is bound to the binding group (one terminal)) or a sidechain of the hydrocarbon group.

The hydrophilic group is a functional group having a polarity (or inother words, polar group), and examples thereof include a carboxylgroup, a hydroxyl group, a phosphoric acid group, an amino group, asulfo group, a carbonyl group, a cyano group, a nitro group, an aldehydegroup, a thiol group and the like. One or more of the hydrophilic groupsare contained in the hydrophilic organic compound.

Examples of the organic group containing a carboxyl group (carboxylgroup-containing organic group) include carboxyaliphatic groupsincluding carboxysaturated aliphatic groups such as 3-carboxypropyl,4-carboxybutyl, 6-carboxyhexyl, 8-carboxyoctyl and 10-carboxydecyl andcarboxyunsaturated aliphatic groups such as carboxybutenyl, and thelike. Other examples of the organic group containing a carboxyl groupinclude carboxyalicyclic groups such as carboxycyclohexyl,carboxyaraliphatic groups such as carboxyphenylhexyl, carboxyaromaticgroups such as carboxyphenyl, and the like.

Examples of the organic group containing a hydroxyl group (hydroxylgroup-containing organic group) include hydroxysaturated aliphaticgroups (hydroxy aliphatic groups) such as 4-hydroxybutyl,6-hydroxylhexyl and 8-hydroxyoctyl, hydroxyaraliphatic groups such as4-hydroxybenzyl, 2-(4-hydroxyphenyl)ethyl, 3-(4-hydroxyphenyl)propyl and6-(4-hydroxyphenyl)hexyl, hydroxyaromatic groups such as hydroxy phenyl,and the like.

Examples of the organic group containing a phosphoric acid group(phosphoric acid group-containing organic group) includephosphonosaturated aliphatic groups (phosphonoaliphatic groups) such as6-phosphonohexyl, phosphonoaraliphatic groups such as6-phosphonophenylhexyl, and the like.

Examples of the organic group containing an amino group (aminogroup-containing organic group) include aminosaturated aliphatic groups(aminoaliphatic groups) such as 6-aminohexyl, aminoaraliphatic groupssuch as 6-aminophenylhexyl, and the like.

Examples of the organic group containing a sulfo group (sulfogroup-containing organic group) include sulphosaturated aliphatic groups(sulphoaliphatic groups) such as 6-sulphohexyl, sulphoaraliphatic groupssuch as 6-sulphophenylhexyl, and the like.

Examples of the organic group containing a carbonyl group (carbonylgroup-containing organic group) include oxosaturated aliphatic groups(oxoaliphatic groups) such as 3-oxopentyl, and the like.

Examples of the organic group containing a cyano group (cyanogroup-containing organic group) include cyanosaturated aliphatic groups(cyanoaliphatic groups) such as 6-cyanohexyl, and the like.

Examples of the organic group containing a nitro group (nitrogroup-containing organic group) include nitrosaturated aliphatic groups(nitroaliphatic groups) such as 6-nitrohexyl, and the like.

Examples of the organic group containing an aldehyde group (aldehydegroup-containing organic group) include aldehydesaturated aliphaticgroups (aldehydealiphatic groups) such as 6-aldehydehexyl, and the like.

Examples of the organic group containing a thiol group (thiolgroup-containing organic group) include thiolsaturated aliphatic groups(thiolaliphatic groups) such as 6-thiolhexyl, and the like.

Specifically, the organic compound containing a hydrophilic group canbe, for example, a carboxyl group-containing organic compound, ahydroxyl group-containing organic compound, a phosphoric acidgroup-containing organic compound, an amino group-containing organiccompound, a sulfo group-containing organic compound, a carbonylgroup-containing organic compound, a cyano group-containing organiccompound, a nitro group-containing organic compound, an aldehydegroup-containing organic compound, a thiol group-containing organiccompound, and the like.

The carboxyl group-containing organic compound can be, for example, adicarboxylic acid or the like in the case where both the binding groupand the hydrophilic group are carboxyl groups. Examples of thedicarboxylic acid include aliphatic dicarboxylic acids includingsaturated aliphatic dicarboxylic acids such as propanedioic acid(malonic acid), butanedioic acid (succinic acid), hexanedioic acid(adipic acid), octanedioic acid, decanedioic acid (sebacic acid) andunsaturated aliphatic dicarboxylic acids such as itaconic acid;alicyclic dicarboxylic acids such as cyclohexyl dicarboxylic acid;araliphatic dicarboxylic acids such as 6-carboxyphenyl hexanoic acid;aromatic dicarboxylic acids such as phthalic acid, terephthalic acid andisophthalic acid; and the like. Also, the carboxyl group-containingorganic compound can be a carboxyl group-containing phosphate ester orthe like in the case where the binding group is a carboxyl group and thehydrophilic group is a phosphoric acid ester group (in the case wherethe inorganic particles include, for example, cerium oxide, strontiumcarbonate or barium sulfate), or in the case where the binding group isa phosphoric acid ester group and the hydrophilic group is a carboxylgroup (in the case where the inorganic particles include, for example,zinc oxide or barium sulfate). Specific examples thereof include ethylcarboxydecylphosphate, ethyl carboxyoctylphosphate, and the like.

The hydroxyl group-containing organic compound can specifically be, forexample, a monohydroxyl carboxylic acid in the case where the bindinggroup is a carboxyl group and the hydrophilic group is a hydroxyl group(in the case where the inorganic particles include, for example, ceriumoxide, strontium carbonate or barium sulfate). Specific examples of themonohydroxyl carboxylic acid include 4-hydroxybutanoic acid,6-hydroxyhexanoic acid, 8-hydroxyoctanoic acid, 4-hydroxyphenylaceticacid, 3-(4-hydroxyphenyl)propionic acid, 6-(4-hydroxyphenyl)hexanoicacid, hydroxybenzoic acid, and the like.

The phosphoric acid group-containing organic compound can be, forexample, a monophosphonocarboxylic acid in the case where the bindinggroup is a carboxyl group and the hydrophilic group is a phosphoric acidgroup (in the case where the inorganic particles include, for example,cerium oxide, strontium carbonate or barium sulfate). Specific examplesthereof include 6-phosphonohexanoic acid, 6-phosphonophenylhexanoicacid, as well as the carboxyl group-containing phosphate esters listedabove.

The amino group-containing organic compound can specifically be, forexample, a monoaminocarboxylic acid in the case where the binding groupis a carboxyl group and the hydrophilic group is an amino group (in thecase where the inorganic particles include, for example, cerium oxide,strontium carbonate or barium sulfate). Specific examples thereofinclude 6-aminohexanoic acid, 6-aminophenylhexanoic acid, and the like.

The sulfo group-containing organic compound can specifically be, forexample, a monosulfocarboxylic acid in the case where the binding groupis a carboxyl group and the hydrophilic group is a sulfo group (in thecase where the inorganic particles include, for example, cerium oxide,strontium carbonate or barium sulfate). Specific examples thereofinclude 6-sulfohexanoic acid, 6-sulfophenylhexanoic acid, and the like.

The carbonyl group-containing organic compound can specifically be, forexample, a monocarbonylcarboxylic acid in the case where the bindinggroup is a carboxyl group and the hydrophilic group is a carbonyl group(in the case where the inorganic particles include, for example, ceriumoxide, strontium carbonate or barium sulfate). Specific examples thereofinclude 4-oxovaleric acid, and the like.

The cyano group-containing organic compound can specifically be, forexample, a monocyanocarboxylic acid in the case where the binding groupis a carboxyl group and the hydrophilic group is a cyano group (in thecase where the inorganic particles include, for example, cerium oxide,strontium carbonate or barium sulfate). Specific examples thereofinclude 6-cyano hexanoic acid, and the like.

The nitro group-containing organic compound can specifically be, forexample, a mononitrocarboxylic acid in the case where the binding groupis a carboxyl group and the hydrophilic group is a nitro group (in thecase where the inorganic particles include, for example, cerium oxide,strontium carbonate or barium sulfate). Specific examples thereofinclude 6-nitro hexanoic acid, and the like.

The aldehyde group-containing organic compound can specifically be, forexample, a monoaldehydecarboxylic acid in the case where the bindinggroup is a carboxyl group and the hydrophilic group is an aldehyde group(in the case where the inorganic particles include, for example, ceriumoxide, strontium carbonate or barium sulfate). A specific example is6-aldehydehexanoic acid.

The thiol group-containing organic compound can specifically be, forexample, a monothiolcarboxylic acid in the case where the binding groupis a carboxyl group and the hydrophilic group is a thiol group (in thecase where the inorganic particles include, for example, cerium oxide,strontium carbonate or barium sulfate). Specific examples include6-thiolhexanoic acid, and the like.

The same or mutually different organic groups may be used.

In the case where mutually different organic groups are used, or inother words, the organic group contains a plurality of different typesof organic groups, a plurality of homologous organic groups and/or aplurality of heterologous organic groups are contained.

Examples of the homologous organic groups include a combination of aplurality of aliphatic groups, a combination of a plurality of alicyclicgroups, a combination of a plurality of araliphatic groups and acombination of a plurality of aromatic groups. Other examples of thehomologous organic groups include a combination of a plurality ofcarboxyaliphatic groups, a combination of a plurality ofcarboxyalicyclic groups, a combination of a plurality ofcarboxyaraliphatic groups, a combination of a plurality ofcarboxyaromatic groups, a combination of a plurality of hydroxyaliphatic groups, a combination of a plurality of hydroxyaraliphaticgroups, a combination of a plurality of hydroxyaromatic groups, acombination of a plurality of phosphonoaliphatic groups, a combinationof a plurality of phosphonoaraliphatic groups, a combination of aplurality of aminoaliphatic groups, a combination of a plurality ofaminoaraliphatic groups, a combination of a plurality of sulphoaliphaticgroups, a combination of a plurality of sulphoaraliphatics, acombination of a plurality of oxoaliphatic groups, a combination of aplurality of cyanoaliphatic groups, a combination of a plurality ofnitroaliphatic groups, a combination of a plurality of aldehydealiphaticgroups, a combination of a plurality of thiolaliphatic groups, and thelike.

As the homologous organic groups, a preferable example is a combinationof a plurality of aliphatic groups, a more preferable example is acombination of a plurality of saturated aliphatic groups, and aparticularly preferable example is a combination of a saturatedaliphatic group having less than 10 carbon atoms and a saturatedaliphatic group having 10 or more carbon atoms, specifically, acombination of hexyl and decyl.

When the organic group contains a plurality of homologous organicgroups, a plurality of organic groups having different sizes (lengthsor/and dimensions, or in other words, the number of carbon atoms) arecontained in the organic group. Accordingly, in a space between adjacentlarger organic groups, a resin molecule enters a gap (pocket) formed inaccordance with the smaller organic group, and the interaction betweenthe larger organic group and the resin molecule can be enhanced. As aresult, the dispersibility of the organic-inorganic composite particlescan be enhanced.

Examples of the heterologous organic groups include a combination of atleast two different groups selected from the group consisting of analiphatic group, an alicyclic group, an araliphatic group, an aromaticgroup, a carboxyaliphatic group, a carboxyalicyclic group, acarboxyaraliphatic group, a carboxyaromatic group, a hydroxy aliphaticgroup, a hydroxyaraliphatic group, a hydroxyaromatic group, aphosphonoaliphatic group, a phosphonoaraliphatic group, anaminoaliphatic group, an aminoaraliphatic group, a sulphoaliphaticgroup, a sulphoaraliphatic group, an oxoaliphatic group, acyanoaliphatic group, a nitroaliphatic group, an aldehydealiphatic groupand a thiolaliphatic group.

A preferable example of the heterologous organic groups is a combinationof an araliphatic group and an aromatic group, and a more preferableexample is a combination of an araliphatic group having 7 to 15 carbonatoms and an aromatic group having 6 to 12 carbon atoms, specifically, acombination of phenylhexyl and phenyl.

Another preferable example of the heterologous organic groups is acombination of an aliphatic group and a hydroxy aliphatic group, a morepreferable example is a combination of a saturated aliphatic group and ahydroxysaturated aliphatic group, and a particularly preferable exampleis a combination of a saturated aliphatic group having 10 or more carbonatoms and a hydroxysaturated aliphatic group having less than 10 carbonatoms, specifically, a combination of decyl and 6-hydroxyhexyl.

As long as the organic group contains a plurality of heterologousorganic groups, when the resin is prepared as a mixture of a pluralityof resin components, the organic group can exert excellent compatibilitywith the resin molecules of the respective resin components havingexcellent compatibility with the organic groups of the respectivegroups. Accordingly, the interaction between the organic groups and theresin molecules of the resin components can be enhanced. As a result,the dispersibility of the organic-inorganic composite particles can beenhanced.

The organic groups are present on the surface of inorganic particles inthe organic-inorganic composite particles. Specifically, the organicgroups are bound to the surface of inorganic particles via a bindinggroup. Also, the organic groups extend from the surface of inorganicparticles toward the outside of the inorganic particles via the bindinggroup.

The organic-inorganic composite particles are produced by subjecting aninorganic substance and an organic compound to a reaction treatment,preferably to a high temperature treatment.

The high temperature treatment is carried out in a solvent. As thesolvent, for example, water and any of the organic compounds listedabove can be used.

Specifically, the organic-inorganic composite particles are obtained bysubjecting an inorganic substance and an organic compound to a hightemperature treatment in water under high pressure conditions(hydrothermal synthesis: hydrothermal reaction), or subjecting aninorganic substance to a high temperature treatment in an organiccompound (high temperature treatment in an organic compound). In otherwords, the organic-inorganic composite particles are obtained bysurface-treating the surface of inorganic particles formed by aninorganic substance with an organic compound.

In the hydrothermal synthesis, for example, the inorganic substance andthe organic compound are reacted under high-temperature andhigh-pressure conditions in the presence of water (first hydrothermalsynthesis).

The inorganic substance subjected to the first hydrothermal synthesis ispreferably a carbonate or a sulfate.

Specifically, first, a reaction system is prepared underhigh-temperature and high-pressure conditions by placing the inorganicsubstance, the organic compound and water in a pressure-resistantairtight container and heating them.

The proportions of respective components per 100 parts by mass of theinorganic substance are as follows: the proportion of the organiccompound is, for example, 1 to 1500 parts by mass, preferably 5 to 500parts by mass and more preferably 5 to 250 parts by mass; and theproportion of water is, for example, 50 to 8000 parts by mass,preferably 80 to 6600 parts by mass and more preferably 100 to 4500parts by mass.

The density of the organic compound is usually 0.8 to 1.1 g/mL, and thusthe proportion of the organic compound is, for example, 1 to 1500 mL,preferably 5 to 500 mL and more preferably 5 to 250 mL per 100 g of theinorganic substance.

Also, the number of moles of the organic compound may be, for example,0.01 to 1000 mol, preferably 0.02 to 50 mol, and more preferably 0.1 to10 mol per mol of the inorganic substance.

In the case where the organic compound contains a plurality of (forexample, two) different types of organic groups, specifically, the molarratio between an organic compound containing one type of organic groupsand an organic compound containing the other type of organic group is,for example, 10:90 to 99.9:0.1 and preferably 20:80 to 99:1.

Also, the density of water is usually approximately 1 g/mL, and thus theproportion of water is, for example, 50 to 8000 mL, preferably 80 to6600 mL, and more preferably 100 to 4500 mL per 100 g of the inorganicsubstance.

Specific reaction conditions for the hydrothermal reaction are asfollows. The heating temperature is, for example, 100 to 500° C. andpreferably 200 to 400° C. The pressure is, for example, 0.2 to 50 MPa,preferably 1 to 50 MPa and more preferably 10 to 50 MPa. The reactiontime is, for example, 1 to 200 minutes and preferably 3 to 150 minutes.In the case where a continuous reactor is used, the reaction time can beset to one minute or less.

The reaction product obtained by the above reaction includes aprecipitate that mostly precipitates in water and a deposit that adheresto the inner wall of the airtight container.

The precipitate is obtained by, for example, sedimentation separation inwhich the reaction product is settled by gravity or a centrifugal field.Preferably, the precipitate is obtained as a precipitate of the reactionproduct by centrifugal sedimentation (centrifugal separation) in whichthe reaction product is settled by a centrifugal field.

The deposit is recovered by, for example, a scraper (spatula) or thelike.

The reaction product can also be recovered (separated) by adding asolvent to wash away an unreacted organic compound (or in other words,dissolving the organic compound in the solvent) and thereafter removingthe solvent.

The solvent can be, for example, an alcohol (hydroxyl group-containingaliphatic hydrocarbon) such as methanol, ethanol, propanol orisopropanol, a ketone (carbonyl group-containing aliphatic hydrocarbon)such as acetone, methyl ethyl ketone, cyclohexanone or cyclopentanone,an aliphatic hydrocarbon such as pentane, hexane or heptane, ahalogenated aliphatic hydrocarbon such as dichloromethane, chloroform ortrichloroethane, a halogenated aromatic hydrocarbon such aschlorobenzene or dichlorobenzene, an ether such as tetrahydrofuran, anaromatic hydrocarbon such as benzene, toluene or xylene, an aqueous pHadjusting solution such as aqueous ammonia, or the like. An alcohol ispreferable.

The washed reaction product is separated from the solvent (supernatantliquid) by, for example, filtration, decantation or the like, andrecovered. After that, the reaction product is dried by, for example,application of heat, an air stream or the like if necessary.

In this manner, the organic-inorganic composite particles having anorganic group on the surface of inorganic particles are obtained.

In the first hydrothermal synthesis, the inorganic substance beforereaction and the inorganic substance after reaction that forms inorganicparticles are the same.

Alternatively, by subjecting an inorganic substance (starting material)and an organic compound to a hydrothermal synthesis, it is also possibleto obtain organic-inorganic composite particles containing inorganicparticles formed of an inorganic substance that is different from theinorganic substance serving as the starting material (secondhydrothermal synthesis).

The inorganic substance subjected to the second hydrothermal synthesiscan be, for example, a hydroxide, a metal complex, a nitrate, a sulfateor the like. A hydroxide and a metal complex are preferable.

In the hydroxide, the element (element that constitutes a cation thatcombines with a hydroxyl ion (OH⁻)) contained in the hydroxide can bethe same as the element that combines with oxygen in an oxide listedabove.

Specifically, the hydroxide can be, for example, titanium hydroxide(Ti(OH)₄) or cerium hydroxide (Ce(OH)₄).

In the metal complex, the metal element contained in the metal complexis a metal element that constitutes a composite oxide with the metalcontained in the hydroxide, and examples thereof include titanium, iron,tin, zirconium and the like. Titanium is preferable.

The ligand of the metal complex can be, for example, amonohydroxycarboxylic acid such as 2-hydroxyoctanoic acid, or the like.

Examples of the metal complex include 2-hydroxyoctanoic acid titanateand the like. The metal complex can be obtained by preparation from ametal element and a ligand described above.

As the organic compound, for example, the same organic compounds asthose that can be used in the first hydrothermal synthesis describedabove can be used.

In the second hydrothermal synthesis, the inorganic substance and theorganic compound are reacted under high-temperature and high-pressureconditions in the presence of water.

The proportions of respective components per 100 parts by mass of theinorganic compound are as follows: the proportion of the organiccompound is, for example, 1 to 1500 parts by mass, preferably 5 to 500parts by mass, and more preferably 5 to 250 parts by mass; and theproportion of water is, for example, 50 to 8000 parts by mass,preferably 80 to 6600 parts by mass, and more preferably 80 to 4500parts by mass.

The proportion of the organic compound is, for example, 0.9 to 1880 mL,preferably 4.5 to 630 mL, and more preferably 4.5 to 320 mL per 100 g ofthe hydroxide, and the number of moles of the organic compound may be,for example, 0.01 to 10000 mol, and preferably 0.1 to 10 mol per mol ofthe hydroxide.

The proportion of water is, for example, 50 to 8000 mL, preferably 80 to6600 mL, and more preferably 5 to 4500 mL per 100 g of the hydroxide.

The reaction conditions for the second hydrothermal synthesis are thesame as those for the first hydrothermal synthesis described above.

In this manner, the organic-inorganic composite particles containing anorganic group on the surface of inorganic particles formed of aninorganic substance that is different from the inorganic substanceserving as a starting material are obtained.

In the formulation used in the second hydrothermal synthesis, a carbonicacid source or a hydrogen source can be blended with the componentsdescribed above.

The carbonic acid source can be, for example, carbon dioxide (carbonicacid gas), formic acid and/or urea.

The hydrogen source can be, for example, hydrogen (hydrogen gas), anacid such as formic acid or lactic acid, a hydrocarbon such as methaneor ethane, or the like.

The proportion of the carbonic acid source or hydrogen source is, forexample, 5 to 140 parts by mass and preferably 10 to 70 parts by massper 100 parts by mass of the inorganic substance.

The proportion of the carbonic acid source can be, for example, 5 to 100mL and preferably 10 to 50 mL per 100 g of the inorganic substance. Thenumber of moles of the carbonic acid source can be, for example, 0.4 to100 mol, preferably 1.01 to 10.0 mol and more preferably 1.05 to 1.30mol per mol of the inorganic substance.

The proportion of the hydrogen source can be, for example, 5 to 100 mLand preferably 10 to 50 mL per 100 g of the inorganic substance. Thenumber of moles of the hydrogen source can be, for example, 0.4 to 100mol, preferably 1.01 to 10.0 mol and more preferably 1.05 to 2.0 mol permol of the inorganic substance.

In the high temperature treatment in an organic compound, an inorganicsubstance and an organic compound are blended and heated under, forexample, normal atmospheric pressure conditions. The organic compound issubjected to the high-temperature treatment while serving as an organicgroup-introducing compound as well as a solvent for dispersing ordissolving the inorganic substance.

The proportion of the organic compound is, for example, 10 to 10000parts by mass and preferably 100 to 1000 parts by mass per 100 parts bymass of the inorganic substance. The proportion of the organic compoundin terms of volume is, for example, 10 to 10000 mL and preferably 100 to1000 mL per 100 g of the inorganic substance.

The heating temperature is, for example, a temperature above 100° C.,preferably 125° C. or higher, and more preferably 150° C. or higher,and, usually for example, 300° C. or lower, and preferably 275° C. orlower. The heating time is, for example, 1 to 60 minutes and preferably3 to 30 minutes.

There is no particular limitation on the shape of the organic-inorganiccomposite particles (primary particles) obtained in the above-describedmanner, and for example the organic-inorganic composite particles may beanisotropic or isotropic, with an average particle size (maximum lengthin the case where they are anisotropic) of, for example, 200 μm or less,preferably 1 nm to 200 μm, more preferably 3 nm to 50 μm andparticularly preferably 3 nm to 10 μm.

As will be described in detail in the examples given below, the averageparticle size of the organic-inorganic composite particles is determinedby measurement by dynamic light scattering (DLS) and/or calculated froma transmission electron microscopic (TEM) or scanning electronmicroscopic (SEM) image analysis.

If the average particle size is below the above range, the proportion ofthe volume of the organic group relative to the surface of theorganic-inorganic composite particles will be high, and the function ofthe inorganic particles is unlikely to be obtained.

If, on the other hand, the average particle size exceeds the aboverange, the organic-inorganic composite particles may be crushed whenmixed with the resin or the like.

The organic-inorganic composite particles thus obtained are unlikely tocoagulate in a dry state, and even if the organic-inorganic compositeparticles appear coagulated in a dry state, the coagulation (formationof secondary particles) will be reliably prevented in theparticle-dispersed resin composition and the particle-dispersed resinmolded article, and therefore the organic-inorganic composite particlesare dispersed substantially uniformly in the resin as primary particles.

In other words, the organic-inorganic composite particles have at leasta configuration that does not allow the inorganic particles to contactwith each other by steric hindrance of the organic group.

In the organic-inorganic composite particles, the proportion of thesurface area of the organic group relative to the surface area of theinorganic particles, or in other words, the surface coverage by theorganic group in the organic-inorganic composite particles (=(surfacearea of organic group/surface area of inorganic particles)×100) is, forexample, 30% or greater and preferably 60% or greater and usually 200%or less.

To calculate the surface coverage, first, the shape of the inorganicparticles is checked with a transmission electron microscope (TEM), theaverage particle size is then calculated, and the specific surface areaof the particles is calculated from the shape of the inorganic particlesand the average particle size. Alternatively, the proportion of theorganic group in the organic-inorganic composite particles is calculatedfrom the weight change as a result of the organic-inorganic compositeparticles being heated to 800° C. with a differential thermal balance(TG-DTA). After that, the amount of the organic group per particle iscalculated from the molecular weight of the organic group, the particledensity and the average volume. Then, the surface coverage is determinedfrom the calculated results.

In the case where at least the surface coverage is high and the organicgroup of the organic-inorganic composite particles has a lengthsufficient to cancel the electric charge of the inorganic particles, thetype of solvent (medium) for dispersing the organic-inorganic compositeparticles can be controlled (designed or managed) according to the typeof organic group.

The organic-inorganic composite particles obtained in theabove-described manner can be subjected to wet classification.

That is, a solvent is added to the organic-inorganic compositeparticles, and the resulting mixture is stirred and allowed to standstill, and thereafter separated into a supernatant and a precipitate.The solvent varies depending on the type of organic groups, but forexample, the same solvents as those listed above can be used.Preferably, the solvent is a hydroxyl group-containing aliphatichydrocarbon, a carbonyl group-containing aliphatic hydrocarbon, analiphatic hydrocarbon, a halogenated aliphatic hydrocarbon or an aqueouspH adjusting solution.

After that, the supernatant is recovered, and it is thereby possible toobtain organic-inorganic composite particles having a small particlesize.

With the wet classification, the average particle size of the resultingorganic-inorganic composite particles (primary particles) can beadjusted to, for example, 1 nm to 450 nm, preferably 3 nm to 200 nm andmore preferably 3 nm to 100 nm.

It is also possible to select the resin and the organic-inorganiccomposite particles such that the solubility parameters (SP values)thereof satisfy a predetermined relationship.

Specifically, the resin and the organic-inorganic composite particlesare selected so as to attain a predetermined SP difference (ΔSP,specifically, the absolute value of the difference between thesolubility parameter of resin (SP_(RESIN) value) and the solubilityparameter of organic-inorganic composite particles (SP_(PARTICLE)value)).

Preferable hydrophilic groups included in both the functional group andthe organic group are a carboxyl group and a hydroxyl group, andpreferable hydrophobic groups included in both the functional group andthe organic group are a hydrocarbon group and the like. The affinitybetween the organic-inorganic composite particles and the resin can beenhanced as a result of both the functional group and the organic grouphaving any of the above groups having the same property (hydrophilicityor hydrophobicity).

Specifically, in order to prepare a particle-dispersed resincomposition, for example, a solvent, organic-inorganic compositeparticles and a resin are blended, and the resulting mixture is stirred(solution preparation). The thus-prepared particle-dispersed resincomposition is a varnish (solution) containing a solvent.

There is no particular limitation on the solvent, and the solvent can beany of the solvents used in washing described above. Other examplesinclude alicyclic hydrocarbons such as cyclopentane and cyclohexane;esters such as ethyl acetate; polyols such as ethylene glycol andglycerol; nitrogen-containing compounds such as N-methylpyrrolidone,pyridine, acetonitrile and dimethylformamide; acryl-based monomers suchas isostearyl acrylate, lauryl acrylate, isoboronyl acrylate, butylacrylate, methacrylate, acrylic acid, tetrahydrofurfuryl acrylate,1,6-hexanediol diacrylate, 2-hydroxyethyl acrylate, 4-hydroxybutylacrylate, phenoxyethyl acrylate, and acryloylmorpholine; vinylgroup-containing monomers such as styrene and ethylene; epoxy-containingmonomers such as bisphenol A epoxy; and the like.

These solvents can be used singly or in a combination of two or more. Ahalogenated aliphatic hydrocarbon and an aqueous pH adjusting solutionare preferable.

Specifically, in order to prepare a particle-dispersed resincomposition, first, the above solvent and a resin are blended so as todissolve the resin in the solvent to prepare a resin solution. Afterthat, the resin solution is blended with organic-inorganic compositeparticles, and the resulting mixture is stirred to prepare aparticle-dispersed resin composition (first preparation method).

The proportion of resin per 100 parts by mass of the resin solution is,for example, 40 parts by mass or less, preferably 35 parts by mass orless, and more preferably 30 parts by mass or less, and usually 1 partby mass or greater. If the proportion of resin exceeds the above range,the solubility of resin may be low.

The proportion of the organic-inorganic composite particles per 100parts by mass of the solids content (resin) of the resin solution is,for example, 1 to 1000 parts by mass, preferably 5 to 500 parts by massand more preferably 10 to 300 parts by mass. Also, the proportion of theorganic-inorganic composite particles per 100 parts by mass of the totalamount of the resin solution (the total amount of the resin and thesolvent) is, for example, 0.1 to 300 parts by mass, preferably 1 to 200parts by mass and more preferably 3 to 100 parts by mass.

Also, the particle-dispersed resin composition can also be prepared byblending a solvent and organic-inorganic composite particles to dispersethe organic-inorganic composite particles in the solvent to prepare aparticle dispersion, and then blending the particle dispersion with aresin and stirring the resulting mixture (second preparation method).

In the particle dispersion, the organic-inorganic composite particlesare dispersed in the solvent as primary particle.

The proportion of the organic-inorganic composite particles per 100parts by mass of the particle dispersion is, for example, 0.1 to 70parts by mass, preferably 0.2 to 60 parts by mass, and more preferably0.5 to 50 parts by mass.

The proportion of resin per 100 parts by mass of the solids content(organic-inorganic composite particles) of the particle dispersion is,for example, 10 to 10000 parts by mass, preferably 20 to 2000 parts bymass and more preferably 40 to 1000 parts by mass.

Furthermore, the particle-dispersed resin composition can also beprepared by, for example, blending a solvent, organic-inorganiccomposite particles and a resin simultaneously and stirring theresulting mixture (third preparation method).

The proportions of respective components per 100 parts by mass of thetotal amount of the particle-dispersed resin composition are as follows:the proportion of the organic-inorganic composite particles is, forexample, 0.1 to 50 parts by mass, preferably 1 to 40 parts by mass andmore preferably 3 to 30 parts by mass; and the proportion of resin is,40 parts by mass or less, preferably 35 parts by mass or less and morepreferably 30 parts by mass or less, and unusually 1 part by mass orgreater. The proportion of the solvent is the remainder obtained byexcluding the organic-inorganic composite particles and the resin fromthe particle-dispersed resin composition.

The particle-dispersed resin composition can also be prepared by, first,preparing a resin solution and a particle dispersion in a separatemanner, and then blending and stirring the resin solution and theparticle dispersion (fourth preparation method).

The proportion of resin in the resin solution is the same as those shownin the first preparation method described above.

The proportion of the organic-inorganic composite particles in theparticle dispersion is the same as those shown in the second preparationmethod described above.

The resin solution and the particle dispersion are blended such that theproportion of resin relative to the organic-inorganic compositeparticles in terms of mass is, for example, 99:1 to 10:90, preferably95:5 to 20:80 and more preferably 90:10 to 30:70.

Furthermore, the particle-dispersed resin composition can also beprepared without the use of a solvent by, for example, melting a resinby application of heat and blending the resin with organic-inorganiccomposite particles (fifth preparation method).

The thus-prepared particle-dispersed resin composition is a melt of theparticle-dispersed resin composition which does not include a solvent.

The heating temperature is, in the case where the resin is athermoplastic resin, greater than or equal to the melting temperature ofthe resin, specifically, 200 to 350° C. In the case where the resin is athermosetting resin, the heating temperature is a temperature at whichthe resin is B-staged, for example, 85 to 140° C.

The proportion of resin relative to the organic-inorganic compositeparticles in terms of mass is, for example, 99:1 to 10:90, preferably95:5 to 20:80 and more preferably 90:10 to 30:70.

In the particle-dispersed resin composition obtained by any of theabove-described preparation methods, the organic-inorganic compositeparticles are uniformly dispersed in the resin. Specifically, in theparticle-dispersed resin composition, the organic-inorganic compositeparticles are dispersed as primary particles in the resin (withoutsubstantial coagulation).

After that, the obtained particle-dispersed resin composition is appliedto, for example, a known support plate to form a coating, and thecoating is dried, whereby a particle-dispersed resin molded article as afilm is molded.

The particle-dispersed resin composition is applied by using, forexample, a known application method such as spin coating or bar coating.Simultaneously with or immediately after application of theparticle-dispersed resin composition, the solvent is removed byvolatilization. If necessary, the solvent can be dried by application ofheat after application of the particle-dispersed resin composition.

The thickness of the obtained film can be set as appropriate accordingto the use and purpose, and the thickness is, for example, 0.1 to 2000μm, preferably 0.5 to 1000 μm and more preferably 1.0 to 500 μm.

The particle-dispersed resin molded article as a film can also be moldedby a melt molding method in which the particle-dispersed resincomposition is extruded by an extruding machine or the like.

The particle-dispersed resin molded article can also be molded as ablock (mass) by injecting the particle-dispersed resin composition intoa metal mold or the like and thereafter subjecting the resultant to, forexample, heat molding such as heat pressing.

In any of the particle-dispersed resin molded articles molded in theabove-described manner, the organic-inorganic composite particles aredispersed as primary particles in the resin.

That is, with a simple method in which a resin and organic-inorganiccomposite particles are blended such that the organic-inorganiccomposite particles are dispersed as primary particles in the resin bysteric hindrance of the organic group, the organic-inorganic compositeparticles can be easily and uniformly dispersed in the resin in theparticle dispersion and the particle-dispersed resin molded article. Inshort, with such a very simple operation, the organic-inorganiccomposite particles can be dispersed as primary particles in the resin.Also, the organic-inorganic composite particles can be dispersed asprimary particles in the resin regardless of the type of inorganicparticles with the above-described simple operation.

Accordingly, the particle-dispersed resin compositions and theparticle-dispersed resin molded articles obtained by the above-describedmethods have excellent clarity because the organic-inorganic compositeparticles are uniformly dispersed in the resin, and therefore they canbe suitably used in various industrial applications including opticalapplications.

Third Embodiment

Embodiment corresponding to the inventions of catalyst particles, acatalyst solution, a catalyst composition and a catalyst molded article,which are included in the third group of inventions

The catalyst particles of the present invention contain inorganicparticles with a catalytic action and an organic group that binds to thesurface of the inorganic particles.

The inorganic particles preferably have a photocatalytic action thatexerts a catalytic action for a gas and/or a liquid (described later) byabsorbing light.

Such catalyst particles can be obtained by, for example,surface-treating an inorganic substance and/or a complex thereof with anorganic compound.

The inorganic substance include a metal composed of a metal element suchas a main group element or a transition element, a nonmetal composed ofa nonmetal element such as boron or silicon, an inorganic compoundcontaining a metal element and/or a nonmetal, or the like.

Examples of the metal element and the nonmetal element include elementsthat are located on the left side and the lower side of a border linethat is assumed to pass through boron (B) of the IIIB group, silicon(Si) of the IVB group, arsenic (As) of the VB group, tellurium (Te) ofthe VIB group and astatine (At) of the VIIB group on the long-formperiodic table (IUPAC, 1989), as well as the elements that are locatedon the border line, and the same elements as those listed in the secondembodiment.

The inorganic compound can be, for example, a hydrogen compound, ahydroxide, a nitride, a halide, an oxide, a carbonate, a sulfate, anitrate, an acetate, a formate, a sulfide, a carbide, a phosphoruscompound, or the like. The inorganic compound may be a compositecompound such as, for example, an oxynitride or a composite oxide.

Among the inorganic substances listed above, a preferable example is aninorganic compound, and more preferable examples are an oxide, asulfate, a nitrate, an acetate, a formate and a composite oxide. Anoxide is particularly preferable.

Examples of the oxide include metal oxides, and preferable examplesinclude titanium oxide (titanium dioxide, titanium oxide (IV), titania:TiO₂), tungsten oxide (tungsten trioxide, tungsten oxide (VI), WO₃),cerium oxide (cerium dioxide, cerium oxide (IV), ceria: CeO₂), zirconiumoxide (zirconium dioxide, zirconium oxide (IV), zirconia: ZrO₂),tantalum oxide (tantalum dioxide, tantalum oxide (IV), TaO₂) and thelike.

The arrangement of atoms in an oxide is not particularly limited, andcan be, for example, either crystalline or non-crystalline (amorphous).

The oxides can be used singly or in a combination of two or more

The sulfate is a compound consisting of a sulfate ion (SO₄ ²⁻) and ametal cation (more specifically, a compound formed by substitution ofthe hydrogen atoms of sulfuric acid (H₂SO₄) with a metal), and the metalelement contained in the sulfate can be, for example, a group IVAelement or a group IB element. Ti and Cu are preferable.

Specifically, the sulfate is preferably titanium sulfate, zirconiumsulfate, hafnium sulfate, copper sulfate, silver sulfate or the like.Titanium sulfate and copper sulfate are more preferable.

The sulfates can be used singly or in a combination of two or more.

The nitrate is a compound consisting of a nitrate ion (NO₃ ⁻) and ametal cation (more specifically, a compound formed by substitution ofthe hydrogen atom of nitric acid (HNO₃) with a metal), and the metalelement contained in the nitrate can be, for example, a group VIIIelement. Pd and Pt are preferable.

Specifically, preferable nitrates are iron nitrate, cobalt nitrate,nickel nitrate, ruthenium nitrate, rhodium nitrate, palladium nitrate,osmium nitrate, iridium nitrate and the like. Palladium nitrate andplatinum nitrate are more preferable.

The nitrates can be used singly or in a combination of two or more.

The acetate is a compound consisting of an acetate ion (CH₃COO⁻) and ametal cation (more specifically, a compound formed by substitution ofthe hydrogen atom of the carboxyl group (—COOH) in acetic acid with ametal), and the metal element contained in the acetate can be, forexample, a group VIII element. Ni is preferable.

Specifically, a preferable acetate is nickel acetate.

The acetates can be used singly or in a combination of two or more.

The formate is a compound consisting of a formate ion (HCOO⁻) and ametal cation (more specifically, a compound formed by substitution ofthe hydrogen atom of the carboxyl group (—COOH) in formic acid with ametal), and the metal element contained in the formate can be, forexample, a group IB element. Cu is preferable.

Specifically, a preferable formate is copper formate.

The formates can be used singly or in a combination of two or more.

The composite oxide is a compound consisting of oxygen and a pluralityof elements, and the plurality of elements is a combination of at leasttwo elements selected from the elements other than oxygen contained inthe oxides listed above, the group I elements, and the group IIelements.

Examples of the group I elements include alkali metals such as Li, Na,K, Rb, and Cs. Examples of the group II elements include the samealkaline earth metals as those listed in the second embodiment.

Examples of the combination of a plurality of elements includecombinations that include at least a group II element such as acombination of a group II element and a group IVB element, a combinationof a group II element and a group VIII element, a combination of a groupII element and a group IVA element, and a combination of a group IIelement and a group VA element; combinations that include at least agroup I element such as a combination of a group I element and a groupIVA element, a combination of a group I element, a group IVA element anda lanthanide series element, and a combination of a group I element anda group VA element; a combination of a group VA element and a group IIBelement; and the like.

Examples of the composite oxide containing at least a group II elementinclude alkaline earth metal titanates, alkaline earth metal zirconates,alkaline earth metal ferrates, alkaline earth metal stannates, alkalineearth metal niobates and the like.

Examples of the composite oxide containing at least a group I elementinclude alkali metal titanates, alkali metal zirconates, alkali metalvanadates, alkali metal niobates and the like.

Examples of the composite oxide containing a group VA element and agroup IIB group element include metal niobates and the like.

Preferable composite oxides are alkaline earth metal titanates, alkalimetal titanates, alkaline earth metal niobates, alkali metal niobatesand metal niobates.

Examples of alkaline earth metal titanates include beryllium titanate(BeTiO₃), magnesium titanate (MgTiO₃), calcium titanate (CaTiO₃),strontium titanate (SrTiO₃), barium titanate (BaTiO₃), bariumtetratitinate (BaTi₄O₉), radium titanate (RaTiO₃) and the like.

Examples of alkali metal titanates include sodium hexatitanate(Na₂Ti₆O₁₃), potassium lanthanum titanate (K₂La₂Ti₃O₁₀) and the like.

Examples of alkaline earth metal niobates include strontium diniobate(Sr₂Nb₂O₇) and the like.

Examples of alkali metal niobates include potassium hexaniobate(K₄Nb₆O₁₇) and the like.

Examples of metal niobates include zinc diniobate (ZnNb₂O₆) and thelike.

The composite oxides can be used singly or in a combination of two ormore.

The complex contains a central atom and/or a central ion and a ligandthat coordinates thereto.

Examples of the central atom include the same metal elements as thoselisted above. Preferable examples include a group IVA element, a groupVIII element and a group IVB element. More preferable examples includeTi, Zr, Fe, Ni, Ru, Sn and the like.

Examples of the central ion include cations of the metal elements listedabove.

Examples of the ligand include coordinating compounds such as carboxylicacid, hydroxycarboxylic acid and acetylacetone; coordinating ions suchas cations and hydroxide ions of the above coordinating compounds; andthe like.

Examples of the carboxylic acid include dicarboxylic acids such asoxalic acid, succinic acid, phthalic acid, and the like.

Examples of the hydroxycarboxylic acid include monohydroxymonocarboxylicacids (specifically, α-monohydroxycarboxylic acids) such as2-hydroxyoctanoic acid, lactic acid and glycolic acid;monohydroxydicarboxylic acids such as malic acid;monohydroxytricarboxylic acids such as citric acid; and the like.

The coordination number is, for example, 1 to 6 and preferably 1 to 3.

The complex can be obtained by preparation from a metal element and aligand described above.

The inorganic substance (specifically, oxide, composite oxide) and thecomplex can be formed (prepared) as salts and/or hydrates. Examples ofthe salts include salts with cations such as ammonium ions.

The inorganic substances and the complexes listed above can be usedsingly or in a combination of two or more.

In the case where an inorganic substance and/or a complex are used incombination, the combination of an inorganic substance and/or a complexcan be, for example, a combination of a plurality of types of inorganicsubstances (first combination) or a combination of an inorganicsubstance and a complex (second combination).

The first combination can be, for example, a combination of a pluralityof types of inorganic substances. Specific examples include acombination of an oxide (first inorganic substance) and at least oneinorganic substance (second inorganic substance) selected from the groupconsisting of metals, sulfates, nitrates and formates.

More specifically, examples of the first combination include acombination of a metal oxide and a metal (group VIII element), acombination of a metal oxide and a sulfate, and a combination of a metaloxide and a formate. Specific examples of the first combination includea combination of tungsten oxide and palladium, a combination of tungstenoxide and platinum, a combination of tungsten oxide and copper sulfate,and a combination of tungsten oxide and copper formate.

Examples of the second combination include a combination of a complexwhose ligand is hydroxycarboxylic acid and a metal, a combination of acomplex whose ligand is hydroxycarboxylic acid, a hydroxide and anacetate, and a combination of a complex whose ligand ishydroxycarboxylic acid, a hydroxide and a complex whose ligand isacetylacetone.

Specific examples of the second combination include a combination of atitanium complex whose central atom is titanium and whose ligand is2-hydroxyoctanoic acid and platinum, a combination of a titanium complexwhose central atom is titanium and whose ligand is 2-hydroxyoctanoicacid, strontium hydroxide and nickel acetate, and a combination of atitanium complex whose central atom is titanium and whose ligand is2-hydroxyoctanoic acid, strontium hydroxide and a ruthenium complexwhose central atom is ruthenium and ligand is acetylacetone.

The organic compound is, for example, an organic group-introducingcompound that introduces (disposes) an organic group on the surface ofinorganic particles. Specifically, the organic compound contains abinding group capable of binding to the surface of inorganic particlesand an organic group. In other words, the organic group is bound to thesurface of inorganic particles via a binding group.

The binding group is selected as appropriate according to the type ofinorganic particles and examples thereof include functional groups suchas phosphoric acid group (—PO(OH)₂, phosphono group), phosphoric acidester group (phosphonate group), carboxyl group, carboxylic acid estergroup (carboxy ester group), amino group, sulfo group, hydroxyl group,thiol group, epoxy group, isocyanate group, nitro group, azo group,silyloxy group, imino group, aldehyde group (acyl group), nitrile groupand vinyl group (polymerizable group). Preferable examples includephosphoric acid group, phosphoric acid ester group, carboxyl group,amino group, sulfo group, hydroxyl group, thiol group, epoxy group, azogroup, vinyl group and the like. More preferable examples includephosphoric acid group, phosphoric acid ester group, carboxyl group,amino group and hydroxyl group.

Phosphoric acid ester groups are, for example, alkyl ester groups ofphosphoric acid (specifically, orthophosphoric acid), or in other words,alkoxy phosphonyls, and can be represented by the following formula (1):

—PO(OR)_(n)H_(2-n)  (1)

where R is an alkyl group having 1 to 3 carbon atoms, and n is aninteger of 1 or 2.

In the above formula (I), the alkyl group represented by R is preferablymethyl or ethyl.

n is preferably 2.

Examples of phosphoric acid ester groups include dialkyl phosphateesters such as dimethyl phosphate esters (dimethoxy phosphonyl:—PO(OCH₃)₂), diethyl phosphate esters (diethoxy phosphonyl:—PO(OC₂H₅)₂), dipropyl phosphate esters (dipropoxy phosphonyl:—PO(OC₃H₇)₂); monoalkyl phosphate esters such as monomethyl phosphateesters (monomethoxy phosphonyl: —PO(OCH₃)H), monoethyl phosphate esters(monoethoxy phosphonyl: —PO(O₂CH₅)H) and monopropyl phosphate esters(monopropoxy phosphonyl: —PO(O₃CH₇)H); and the like. Dialkyl phosphateesters are preferable.

The binding group is selected as appropriate according to the type ofinorganic particles. Specifically, when the inorganic particles containtitanium oxide, for example, a phosphoric acid group and/or a phosphoricacid ester group are selected. When the inorganic particles containtungstic acid (described later), for example, an amino group isselected. When the inorganic particles contain strontium titanate, forexample, a carboxylic acid, a phosphoric acid group and/or a phosphoricacid ester group are selected.

One or more of these binding groups are contained in the organiccompound. Specifically, the binding group is bound to a terminal or aside chain of the organic group.

The organic group includes, for example, a hydrocarbon group such as analiphatic group, an alicyclic group, an araliphatic group or an aromaticgroup, or the like. Examples of the hydrocarbon group include the samehydrocarbon groups as those listed in the second embodiment.

The organic group is a hydrophobic group for imparting hydrophobicity tothe surface of inorganic particles.

Accordingly, the organic compounds containing a hydrophobic groupdescribed above are used as hydrophobic organic compounds forhydrophobic treatment of inorganic particles.

Specific examples of such hydrophobic organic compounds in the casewhere the binding group is a phosphoric acid group include aliphaticgroup-containing phosphonic acids including saturated aliphaticgroup-containing phosphonic acids (saturated phosphonic acids) such asmethylphosphonic acid, hexyl phosphonic acid, octylphosphonic acid anddecylphosphonic acid, and the like. Other examples of the hydrophobicorganic compounds include alicyclic group-containing phosphonic acids(alicyclic phosphonic acids) such as cyclohexyl phosphonic acid;araliphatic group-containing phosphonic acids (araliphatic phosphonicacids) such as 6-phenylhexyl phosphonic acid; aromatic group-containingphosphonic acids (aromatic phosphonic acids) such as phenyl phosphonicacid and toluenephosphonic acid; and the like.

Specific examples of hydrophobic organic compounds in the case where thebinding group is a phosphoric acid ester group include aliphaticgroup-containing phosphonate esters including saturated aliphaticgroup-containing phosphonate esters (saturated phosphonic acid dialkylesters) such as hexyl phosphonic acid diethyl ester, octylphosphonicacid diethyl ester and decylphosphonic acid diethyl ester, and the like.Other examples of the hydrophobic organic compounds include alicyclicgroup-containing phosphonic acid alkyl esters (alicyclic phosphonic aciddialkyl esters) such as cyclohexanephosphonic acid diethyl ester;araliphatic group-containing phosphonate esters (araliphatic phosphonicacid dialkyl esters) such as 6-phenylhexyl phosphonic acid diethylester; aromatic group-containing phosphonic acid alkyl esters (aromaticphosphonic acid dialkyl esters) such as phenyl phosphonic acid diethylester and toluenephosphonic acid diethyl ester; and the like.

Specific examples of hydrophobic organic compounds in the case where thebinding group is a carboxyl group include aliphatic group-containingcarboxylic acids (fatty acids) such as hexanoic acid, octanoic acid anddecanoic acid; araliphatic group-containing carboxylic acids such as6-phenylhexanoic acid; and the like.

Specific examples of hydrophobic organic compounds in the case where thebinding group is an amino group include aliphatic group-containingamines such as hexylamine, octylamine and decylamine; and the like.

Alternatively, the organic compound can also be used as a hydrophilicorganic compound for hydrophilic treatment of inorganic particles. Inthis case, the organic group contained in the hydrophilic organiccompound includes any of the above hydrocarbon groups and a hydrophilicgroup that binds to the hydrocarbon group.

Specifically, in the hydrophilic organic compound, the hydrophilic groupis bound to a terminal (the terminal (the other terminal) opposite theterminal that is bound to the binding group (one terminal)) or a sidechain of the hydrocarbon group.

The hydrophilic group is a functional group having a polarity (or inother words, polar group), and examples thereof include a phosphoricacid group, a phosphoric acid ester group, a hydroxyl group, a carboxylgroup, an amino group, a sulfo group, a carbonyl group, a cyano group, anitro group, an aldehyde group, a thiol group and the like.

Preferable examples of the hydrophilic group include a phosphoric acidgroup, phosphoric acid ester group, a hydroxyl group, a carboxyl group,a carboxylic acid ester group (carboxy ester group), an amino group, anda sulfo group. More preferable examples include a phosphoric acid groupand a phosphoric acid ester group.

One or more of the hydrophilic groups are contained in the hydrophilicorganic compound. In the case where a plurality of hydrophilic groupsare contained in the hydrophilic organic compound, for example, an aminogroup and a sulfo group are used in combination.

Examples of the organic group containing a phosphoric acid group(phosphoric acid group-containing organic group) includephosphonosaturated aliphatic groups (phosphonoaliphatic groups) such as3-phosphonopropyl, 6-phosphonohexyl and 10-phosphonodecyl;phosphonoaraliphatic groups such as 6-phosphonophenylhexyl; and thelike.

Examples of the organic group containing a phosphoric acid ester group(phosphoric acid ester group-containing organic group) includealkoxyphosphonyl hydrocarbon groups including alkoxyphosphonyl saturatedaliphatic groups (alkoxyphosphonyl aliphatic groups) such as3-(diethoxy-phosphonyl)propyl, 6-(diethoxy-phosphonyl)hexyl and10-(diethoxy-phosphonyl)decyl; and alkoxyphosphonyl araliphatic groupssuch as 6-(diethoxy-phosphonyl)phenylhexyl.

Examples of the organic group containing a hydroxyl group (hydroxygroup-containing organic group) include hydroxy aliphatic groups such as10-hydroxydecyl; and the like.

Examples of the organic group containing a carboxyl group (carboxylgroup-containing organic group) include carboxysaturated aliphaticgroups (carboxyaliphatic groups) such as 2-carboxyethyl,3-carboxypropyl, 4-carboxybutyl, 5-carboxypentyl, 6-carboxyhexyl,7-carboxyheptyl, 8-carboxyoctyl, 9-carboxynonyl and 10-carboxydecyl; andthe like.

Examples of the organic group containing a carboxylic acid ester group(carboxy ester group-containing organic group) include carboxy esteraliphatic groups such as 2-(methoxy-carbonyl)ethyl,3-(methoxy-carbonyl)propyl, 4-(methoxy-carbonyl)butyl,5-(methoxy-carbonyl)pentyl, 6-(methoxy-carbonyl)hexyl,7-(methoxy-carbonyl)heptyl, 8-(methoxy-carbonyl)octyl,9-(methoxy-carbonyl)nonyl and 10-(methoxy-carbonyl)decyl.

Examples of the organic group containing an amino group and a sulfogroup (amino group- and sulfo group-containing organic group) includeamino/sulphoaliphatic groups such as 2-amino-3-sulfopropyl.

Specifically, examples of the organic compound containing a hydrophilicgroup include a phosphoric acid group-containing organic compound, aphosphoric acid ester group-containing organic compound, a hydroxylgroup-containing organic compound, a carboxyl ester group-containingorganic compound, an amino group-containing organic compound, a sulfogroup-containing organic compound, a carbonyl group-containing organiccompound, a cyano group-containing organic compound, a nitrogroup-containing organic compound, an aldehyde group-containing organiccompound, a thiol group-containing organic compound and the like.

Preferable examples include a phosphoric acid group-containing organiccompound, a phosphoric acid ester group-containing organic compound, ahydroxyl group-containing organic compound and a carboxy estergroup-containing organic compound.

Examples of the phosphoric acid group-containing organic compound in thecase where the binding group is a phosphoric acid group and the polargroup is a carboxyl group (more specifically, in the case where thephosphoric acid group is bound to the inorganic particles containingtitanium oxide) include monophosphonocarboxylic acids, and specificexamples include 3-phosphono propionic acid, 6-phosphonohexanoic acid,10-phosphono decanoic acid, 6-phosphonophenylhexanoic acid, and thelike.

Examples of the phosphoric acid ester group-containing organic compoundin the case where the binding group is a phosphoric acid ester group andthe polar group is a carboxy ester group (more specifically, in the casewhere the phosphoric acid ester group is bound to the inorganicparticles containing titanium oxide) include3-(diethoxy-phosphonyl)ethyl propionic acid ester,6-(diethoxy-phosphonyl)hexanoic acid ethyl ester,10-(diethoxy-phosphonyl)decanoic acid ethyl ester and the like. Theabove-listed phosphoric acid ester group-containing organic compoundsare also regarded as carboxy ester group-containing organic compounds.

Examples of the phosphoric acid ester group-containing organic compoundin the case where the binding group is a phosphoric acid ester group andthe polar group is a hydroxyl group (more specifically, in the casewhere the phosphoric acid ester group is bound to the inorganicparticles containing titanium oxide) include phosphoric acid estergroup- and hydroxyl group-containing compounds such as10-(diethoxy-phosphonyl)decanol; and the like. The phosphoric acid estergroup- and hydroxyl group-containing compounds are also regarded ashydroxyl group-containing compounds.

The same or mutually different organic groups may be used.

In the case where mutually different organic groups are used, or inother words, the organic group contains a plurality of different typesof organic groups, a plurality of homologous organic groups and/or aplurality of heterologous organic groups are contained.

Examples of the homologous organic groups include a combination of aplurality of aliphatic groups, a combination of a plurality ofphosphonoaliphatic groups, a combination of a plurality ofalkoxyphosphonyl aliphatic groups, a combination of a plurality ofcarboxyaliphatic groups, a combination of a plurality of carboxy esteraliphatic groups, and the like.

The combination of a plurality of aliphatic groups can be, for example,a combination of a saturated aliphatic group having less than 10 carbonatoms and a saturated aliphatic group having 10 or more carbon atoms.Specific examples include a combination of octyl and decyl, and acombination of methyl and decyl. Another example of the combination of aplurality of aliphatic groups is a combination of a saturated aliphaticgroup having less than 7 carbon atoms and a saturated aliphatic grouphaving 7 or more carbon atoms. Specific examples include a combinationof methyl and octyl, a combination of hexyl and decyl, and a combinationof hexyl and octyl. Another example is a combination of a saturatedaliphatic group having less than 5 carbon atoms and a saturatedaliphatic group having 5 or more carbon atoms. A specific example is acombination of methyl and hexyl.

Examples of the combination of a plurality of phosphonoaliphatic groupsinclude a combination of a phosphonoaliphatic group having less than 5carbon atoms and a phosphonoaliphatic group having 5 or more carbonatoms. A specific example is a combination of 3-phosphonopropyl and6-phosphonohexyl.

Examples of the combination of a plurality of alkoxyphosphonyl aliphaticgroups include a combination of an alkoxyphosphonyl aliphatic grouphaving less than 10 carbon atoms and an alkoxyphosphonyl aliphatic grouphaving 10 or more carbon atoms. Specific examples include a combinationof 3-(diethoxy-phosphonyl)propyl and 6-(diethoxy-phosphonyl)hexyl, and acombination of 3-(diethoxy-phosphonyl)propyl and10-(diethoxy-phosphonyl)decyl.

Examples of the combination of a plurality of carboxyaliphatic groupsinclude a carboxyaliphatic group having less than 5 carbon atoms and acarboxyaliphatic group having 5 or more carbon atoms. A specific exampleis a combination of 2-carboxyethyl and 5-carboxypropyl.

The combination of a plurality of carboxy ester aliphatic groups can be,for example, a combination of a carboxy ester aliphatic group havingless than 7 carbon atoms and a carboxy ester aliphatic group having 7 ormore carbon atoms. Specific examples include a combination of2-(methoxy-carbonyl)ethyl and 5-(methoxy-carbonyl)heptyl, and acombination of 2-(methoxy-carbonyl)ethyl and 9-(methoxy-carbonyl)nonyl.

When the organic group contains a plurality of homologous organicgroups, a plurality of organic groups having different sizes (lengthsor/and dimensions, or in other words, the number of carbon atoms) arecontained in the organic group. Accordingly, in a space between adjacentlarger organic groups, a resin molecule enters a gap (pocket) formed inaccordance with the smaller organic group, and the interaction betweenthe larger organic group and the resin molecule can be enhanced. As aresult, the dispersibility of the catalyst particles can be enhanced.

Examples of the heterologous organic groups include a combination of twodifferent groups selected from the group consisting of an aliphaticgroup, an alicyclic group, an araliphatic group, an aromatic group, aphosphonoaliphatic group, a phosphonoaraliphatic group, analkoxyphosphonyl aliphatic group, an alkoxyphosphonyl araliphatic group,a hydroxy aliphatic group, a carboxyaliphatic group, acarboxyaraliphatic group, a carboxyaromatic group, a carboxy esteraliphatic group and an amino/sulphoaliphatic group.

Preferable examples of the heterologous organic groups include acombination of an aliphatic group and an araliphatic group, acombination of an aliphatic group and a carboxyaliphatic group, acombination of an aliphatic group and a carboxy ester aliphatic group,and a combination of a carboxyaliphatic group and a carboxy esteraliphatic group.

The combination of an aliphatic group and an araliphatic group can be,for example, a combination of a saturated aliphatic group having 6 to 12carbon atoms and an araliphatic group having 7 to 15 carbon atoms, and aspecific example is a combination of octyl and phenylhexyl.

The combination of an aliphatic group and a carboxyaliphatic group canbe, for example, a combination of an aliphatic group having less than 6carbon atoms and a carboxyaliphatic group having less than 6 carbonatoms. Specific examples include a combination of methyl and2-carboxyethyl and a combination of methyl and 5-carboxypentyl. Anotherexample is a combination of an aliphatic group having 6 or more carbonatoms and a carboxyaliphatic group having less than 6 carbon atoms, andspecific examples include a combination of octyl and 2-carboxyethyl anda combination of octyl and 5-carboxypentyl.

The combination of an aliphatic group and a carboxy ester aliphaticgroup can be, for example, a combination of an aliphatic group havingless than 6 carbon atoms and a carboxy ester aliphatic group having lessthan 6 carbon atoms, and a specific example is a combination of methyland 2-(methoxy-carbonyl)ethyl.

Also, the combination of an aliphatic group and a carboxy esteraliphatic group can be, for example, a combination of an aliphatic grouphaving less than 6 carbon atoms and a carboxy ester aliphatic grouphaving 6 or more carbon atoms, and a specific example is a combinationof methyl and 9-(methoxy-carbonyl)nonyl.

Another example of the combination of an aliphatic group and a carboxyester aliphatic group is a combination of an aliphatic group having 7 ormore carbon atoms and a carboxy ester aliphatic group having 7 or morecarbon atoms, and specific examples include a combination of octyl and9-(methoxy-carbonyl)nonyl and a combination of decyl and9-(methoxy-carbonyl)nonyl.

Another example of the combination of an aliphatic group and a carboxyester aliphatic group is a combination of an aliphatic group having 6 ormore carbon atoms and a carboxy ester aliphatic group having less than 6carbon atoms, and a specific example is a combination of decyl and2-(methoxy-carbonyl)ethyl.

The combination of a carboxyaliphatic group and a carboxy esteraliphatic group can be, for example, a combination of a carboxyaliphaticgroup having less than 5 carbon atoms and a carboxy ester aliphaticgroup having 6 or more carbon atoms, and a specific example is acombination of 2-carboxyethyl and 9-(methoxy-carbonyl)nonyl.

As long as the organic group contains a plurality of heterologousorganic groups, when the resin is prepared as a mixture of a pluralityof resin components, the organic group can exert excellent compatibilitywith the resin molecules of the respective resin components havingexcellent compatibility with the organic groups of the respectivegroups. Accordingly, the interaction between the organic groups and theresin molecules of the resin components can be enhanced. As a result,the dispersibility of the catalyst particles can be enhanced.

The organic groups are present on the surface of inorganic particles inthe catalyst particles. Specifically, the organic groups extend from thesurface of inorganic particles toward the outside of the inorganicparticles via a binding group.

The catalyst particles are produced by subjecting an inorganic substanceand/or a complex and an organic compound to a reaction treatment,preferably to a high temperature treatment.

The high temperature treatment is carried out in a solvent. As thesolvent, for example, water and any of the organic compounds listedabove can be used.

Specifically, the catalyst particles are obtained by surface-treating(hydrothermal synthesis: hydrothermal reaction) an inorganic substanceand/or a complex with an organic compound in hot high pressure water, orsurface-treating an inorganic substance and/or a complex in a hotorganic compound. In other words, the catalyst particles are obtained bysurface-treating the surface of (inorganic particles formed of) theinorganic substance and/or the complex with any of the organic compoundscontaining an organic group listed above.

In the hydrothermal synthesis, for example, the inorganic substance andthe organic compound are reacted under high-temperature andhigh-pressure conditions in the presence of water (first hydrothermalsynthesis).

Preferable examples of the inorganic substance subjected to the firsthydrothermal synthesis include an oxide, a sulfate, a nitrate, aformate, a hydroxide and a metal.

The inorganic substances subjected to the first hydrothermal synthesiscan be used singly or in combination. In the case where the inorganicsubstances are used in combination, the first combination mentionedabove is used.

To carry out the first hydrothermal synthesis, first, a reaction systemis prepared under high-temperature and high-pressure conditions byplacing an inorganic substance, an organic compound and water in apressure-resistant airtight container and heating them.

The proportions of respective components are the same as those (in termsof mass, volume, mol, and the like) shown in the second embodiment.

Particularly when the inorganic substances are used in combination,specifically, when the first combination is used, the amount of thefirst inorganic substance is greater than that of the second inorganicsubstance when they are blended. Specifically, the proportion of thesecond inorganic substance per 100 parts by mass of the first inorganicsubstance is, for example, 20 parts by mass or less, preferably 10 partsby mass or less, and more preferably 5 parts by mass or less, andusually 0.01 parts by mass or greater. In other words, the proportion ofthe second inorganic substance per mol of the first inorganic substanceis, for example, 0.2 mol or less, preferably 0.1 mol or less, and morepreferably 0.05 mol or less, and usually 0.0001 mol or greater.

Specific reaction conditions for the hydrothermal reaction are asfollows. The heating temperature is, for example, 100 to 600° C., andpreferably 200 to 500° C. The pressure is, for example, 0.2 to 50 MPa,preferably 1 to 50 MPa, and more preferably 10 to 50 MPa. The reactiontime is, for example, 1 to 2000 minutes, preferably 2 to 1000 minutes,and more preferably 3 to 500 minutes. In the case where a continuousreactor is used, the reaction time is set to, for example, one minute orless.

The reaction product obtained by the above reaction includes aprecipitate that mostly precipitates in water and a deposit that adheresto the inner wall of the airtight container.

The precipitate is obtained by, for example, sedimentation separation inwhich the reaction product is settled by gravity or a centrifugal field.Preferably, the precipitate is obtained as a precipitate of the reactionproduct by centrifugal sedimentation (centrifugal separation) in whichthe reaction product is settled by a centrifugal field.

The deposit is recovered by, for example, a scraper (spatula) or thelike.

The reaction product can also be recovered (separated) by adding asolvent to wash away an unreacted organic compound (or in other words,dissolving the organic compound in the solvent) and thereafter removingthe solvent.

As the solvent, the same solvents as those listed in the secondembodiment can be used.

The washed reaction product is separated from the solvent (supernatantliquid) by, for example, filtration, decantation or the like, andrecovered. After that, the reaction product is dried by, for example,application of heat, an air stream or the like if necessary.

In this manner, the catalyst particles containing inorganic particlesand an organic group that binds to the surface of the inorganicparticles are obtained.

Alternatively, unlike the first hydrothermal synthesis, by subjecting aninorganic substance and/or a complex (starting material) and an organiccompound to a hydrothermal synthesis, it is possible to obtain catalystparticles containing inorganic particles formed of an inorganicsubstance and/or a complex that is/are different from the startingmaterial (second hydrothermal synthesis).

Examples of the inorganic substance subjected to the second hydrothermalsynthesis include a hydroxide, a sulfate, an acetate, a metal, hydratesthereof and the like.

In the hydroxide, the element (element that constitutes a cation thatcombines with a hydroxyl ion (OH⁻)) contained in the hydroxide can bethe same as the element that combines with oxygen in an oxide listedabove.

Specifically, the hydroxide can be, for example, strontium hydroxide(Sr(OH)₂) or the like.

The complex subjected to the second hydrothermal synthesis can be, forexample, titanium complex or the like.

Examples of the hydrates subjected to the second hydrothermal synthesisinclude tungstic acid (WO₃.H₂O), ammonium tungstate pentahydrate((NH₄)₂WO₄.5H₂O) and the like. These hydrates produce tungsten oxide asa result of elimination of water of hydration in the second hydrothermalsynthesis.

Such inorganic substances and complexes (raw materials) can be usedsingly or in a combination of two or more.

In the case where the raw materials subjected to the second hydrothermalsynthesis are used in combination, the first combination and the secondcombination mentioned above are used.

In the case where the first combination is used, and the secondinorganic substance is a metal, the second inorganic substance does notcause a change in the chemical composition before and after the reaction(second hydrothermal synthesis).

Specific examples of the second inorganic substance subjected to thesecond hydrothermal synthesis in the first combination includepalladium, platinum and the like. These elements do not cause a changein the chemical composition before and after the reaction (secondhydrothermal synthesis).

After the second hydrothermal synthesis, the metal or oxide forming thesecond inorganic substance is supported on the first inorganicsubstance.

The term “supported” as used herein is defined as the state in which themetal or oxide is present substantially uniformly inside of and/or onthe surface of the first inorganic substance.

Specifically, a metal (copper) forming a sulfate (copper) is supportedon an oxide (tungsten oxide) after the second hydrothermal synthesis.Also, a group VIII element (palladium or platinum) is supported on anoxide (tungsten oxide) after the second hydrothermal synthesis.Furthermore, a metal (copper) forming a formate (copper formate) issupported on tungsten oxide after the second hydrothermal synthesis.

The proportions of respective components in the second hydrothermalsynthesis per 100 parts by mass of the inorganic substance and thecomplex are as follows: the proportion of the organic compound is, forexample, 1 to 1500 parts by mass, preferably 5 to 500 parts by mass andmore preferably 5 to 250 parts by mass; and the proportion of water is,for example, 50 to 8000 parts by mass, preferably 80 to 6600 parts bymass and more preferably 80 to 4500 parts by mass.

The proportion of the organic compound is, for example, 0.9 to 1880 mL,preferably 4.5 to 630 mL and more preferably 4.5 to 320 mL per 100 g ofthe inorganic substance and the complex, and the number of moles of theorganic compound may be, for example, 0.01 to 10000 mol and preferably0.1 to 10 mol per mol of the inorganic substance and the complex.

The proportion of water is, for example, 50 to 8000 mL, preferably 80 to6600 mL and more preferably 100 to 4500 mL per 100 g of the inorganicsubstance and the complex.

In the case where an inorganic substance and a complex are used incombination, the second combination mentioned above is used. Morespecifically, when a combination of a complex and an inorganic substanceis used, the proportion of the inorganic substance per 100 parts by massof the complex is, for example, 10 parts by mass or less, preferably 8parts by mass or less and more preferably 5 parts by mass or less, andusually 0.001 parts by mass or greater. In other words, the proportionof the inorganic substance per mol of the complex is, for example, 0.1mol or less, preferably 0.08 mol or less and more preferably 0.05 mol orless, and usually 0.00001 mol or greater.

In the case where a plurality of complexes are used, specifically, inthe case where a combination of a titanium complex and a rutheniumcomplex is used, the proportion of the ruthenium complex per 100 partsby mass of the titanium complex is, for example, 50 parts by mass orless, preferably 25 parts by mass or less and usually 0.1 parts by massor greater. In other words, the proportion of the ruthenium complex permol of the titanium complex is, for example, 0.5 mol or less, preferably0.25 mol or less, and usually 0.0001 mol or greater.

The reaction conditions for the second hydrothermal synthesis are thesame as those for the first hydrothermal synthesis described above.

In the case where a combination of a titanium complex and platinum isused as the second combination, the titanium complex produces titaniumoxide as a result of the reaction (second hydrothermal synthesis) whileplatinum does not cause a change in the chemical reaction in thechemical composition before and after the reaction. Also, in the casewhere a combination of a titanium complex, strontium hydroxide andnickel acetate is used as the second combination, the titanium complexand strontium hydroxide produce strontium titanate (SrTiO₃) as a resultof the reaction (second hydrothermal synthesis) while nickel acetateproduces nickel oxide (NiO). Furthermore, in the case where acombination of a titanium complex, strontium hydroxide and a rutheniumcomplex is used as the second combination, the titanium complex andstrontium hydroxide produce strontium titanate (SrTiO₃) as a result ofthe reaction (second hydrothermal synthesis), while the rutheniumcomplex produces ruthenium oxide (RuO₂).

In this manner, the catalyst particles containing inorganic particlesformed of an inorganic substance that is different from the inorganicsubstance serving as a starting material and a complex, and an organicgroup that binds to the surface of the inorganic particles are obtained.

In the formulations used in the first hydrothermal synthesis and thesecond hydrothermal synthesis, a pH adjusting agent can be blended withthe components in an appropriate proportion.

The pH adjusting agent can be, for example, an aqueous ammonia solution,an aqueous sodium hydroxide solution or the like.

In the surface treatment performed in a hot organic compound, aninorganic substance and/or a complex and an organic compound are blendedand heated, for example, under normal atmospheric pressure conditions.The organic compound is subjected to the high temperature treatmentwhile serving as an organic group-introducing compound as well as asolvent for dispersing or dissolving the inorganic substance and/or thecomplex.

The proportion of the organic compound is, for example, 1 to 10000 partsby mass, preferably 10 to 5000 parts by mass, and more preferably 20 to1000 parts by mass per 100 parts by mass of the inorganic substance andthe complex. The proportion of the organic compound in terms of volumeis, for example, 1 to 10000 mL, preferably 10 to 5000 mL, and morepreferably 20 to 1000 mL per 100 g of the inorganic substance and thecomplex.

The heating temperature is, for example, a temperature above 100° C.,preferably 125° C. or higher, and more preferably 150° C. or higher, andusually for example, 600° C. or lower. The heating time is, for example,1 to 2000 minutes, preferably 2 to 1000 minutes, and more preferably 3to 500 minutes. In the case where a continuous reactor is used, thereaction time is set to, for example, one minute or less.

Also, heating can be carried out under, for example, high pressure. Asfor the high pressure conditions, the same pressures as those used inthe hydrothermal synthesis shown above can be used.

Through the surface treatment in a hot organic compound, the catalystparticles containing inorganic particles formed of a metal oxide formingan inorganic substance and/or a complex, and an organic group that bindsto the surface of the inorganic particles are obtained.

The high temperature treatment (surface treatment) described above canbe carried out once, or can be carried out a plurality of times from aview point of enhancing treatment efficiency.

As the method for carrying out the high temperature treatment aplurality of times, for example, a method in which each of the firsthydrothermal synthesis, the second hydrothermal synthesis and thesurface treatment in a hot organic compound is repeated, or a method inwhich the above treatments are carried out in combination is used.Preferably, the method in which the above treatments are carried out incombination is used. More preferably, a method in which the surfacetreatment in a hot organic compound is performed after the secondhydrothermal synthesis is used.

Specifically, organic-inorganic composite particles in which acarboxyaliphatic group is bound to titanium oxide via a phosphoric acidgroup are obtained by subjecting a titanium complex to a hightemperature treatment in any of the phosphoric acid estergroup-containing organic compounds (carboxy ester group-containingorganic compounds) listed above. After that, the obtainedorganic-inorganic composite particles are subjected to a hightemperature treatment in an alcohol, whereby in the organic group, acarboxy ester group-containing organic group is produced from thecarboxyaliphatic group. In other words, a carboxyl group binding to aterminal of an aliphatic group is esterified by the alcohol.

There is no particular limitation on the configuration of the catalystparticles (primary particles) obtained in the above-described manner,and for example the catalyst particles may be anisotropic or isotropic,with an average particle size (average maximum length in the case wherethey are anisotropic) of, for example, 450 nm or less, preferably 1 to450 nm, more preferably 1 to 200 nm and particularly preferably 1 to 100nm from a view point of clarity.

As will be described in detail in the examples given below, the averageparticle size of the catalyst particles is determined by measurement bydynamic light scattering (DLS) or calculated from a transmissionelectron microscopic (TEM) or scanning electron microscopic (SEM) imageanalysis or with the Scherrer's equation based on data of X-raydiffractometry (XRD).

If the average particle size exceeds the above range, the clarity of thecatalyst solution, the catalyst resin composition or the catalyst moldedarticle will be low, or the particles may be crushed when mixed with aresin or the like.

If, on the other hand, the average particle size is below the aboverange, the proportion of the volume of the organic group relative to thesurface of the catalyst particles will be high, and the inorganicparticles may be unlikely to exert its catalytic action.

The catalyst particles thus obtained are unlikely to coagulate in a drystate, and even if the catalyst particles appear coagulated in a drystate, the coagulation (formation of secondary particles) will bereliably prevented in a catalyst composition and a catalyst moldedarticle, and therefore the catalyst particles are dispersedsubstantially uniformly in a resin as primary particles.

In the catalyst particles, the proportion of the surface area of theorganic group relative to the surface area of the inorganic particles,or in other words, the surface coverage by the organic group in thecatalyst particles (=(surface area of organic group/surface area ofinorganic particles)×100) is, for example, 30% or greater and preferably60% or greater and usually 200% or less.

The surface coverage is determined by the same method as that describedin the second embodiment.

In the case where at least the surface coverage is high and the organicgroup of the catalyst particles has a length sufficient to cancel theelectric charge of the inorganic particles, the type of solvent (medium)for dispersing the catalyst particles can be controlled (designed ormanaged) according to the type of organic group.

The catalyst particles obtained in the above-described manner can besubjected to wet classification.

Specifically, a solvent is added to the catalyst particles, and theresulting mixture is stirred and allowed to stand still, and thereafterseparated into a supernatant and a precipitate. The solvent variesdepending on the type of organic group, but for example, the samesolvents as those listed above can be used, and preferable examplesinclude a hydroxyl group-containing aliphatic hydrocarbon, a carbonylgroup-containing aliphatic hydrocarbon, an aliphatic hydrocarbon, ahalogenated aliphatic hydrocarbon and an aqueous pH adjusting solution.

After that, the supernatant is recovered, and it is thereby possible toobtain catalyst particles having a small average particle size.

With the wet classification, the average particle size of the resultingcatalyst particles (primary particles) can be adjusted to, for example,400 nm or less, 1 nm to 400 nm, preferably 1 nm to 200 nm and morepreferably 1 nm to 100 nm.

The catalyst particles obtained in the above-described manner can bedispersed in a solvent or a resin to prepare a catalyst solution or acatalyst composition.

The catalyst solution contains a solvent and catalyst particlesdescribed above.

In order to prepare such a catalyst solution, a solvent and catalystparticles are blended, and the resulting mixture is stirred so as todisperse the catalyst particles in the solvent.

There is no particular limitation on the solvent, and examples thereofinclude solvents used in washing described above. Other examples includealicyclic hydrocarbons such as cyclopentane and cyclohexane; esters suchas ethyl acetate; polyols such as ethylene glycol and glycerol;nitrogen-containing compounds such as N-methylpyrrolidone, pyridine,acetonitrile and dimethylformamide; acrylic monomers such as isostearylacrylate, lauryl acrylate, isoboronyl acrylate, butyl acrylate,methacrylate, acrylic acid, tetrahydrofurfuryl acrylate, 1,6-hexanedioldiacrylate, 2-hydroxyethyl acrylate, 4-hydroxybutyl acrylate,phenoxyethyl acrylate and acryloylmorpholine; vinyl group-containingmonomers such as styrene and ethylene; epoxy-containing monomers such asbisphenol A epoxy; and the like.

These solvents can be used singly or in a combination of two or more. Ahalogenated aliphatic hydrocarbon is preferable.

The proportion of the catalyst particles is, for example, 0.1 to 70parts by mass, preferably 0.2 to 60 parts by mass and more preferably0.5 to 50 parts by mass per 100 parts by mass of the catalyst solution.

In the catalyst solution obtained in this manner, the catalyst particleshave a configuration that does not allow the inorganic particles tocontact with each other, and therefore are uniformly dispersed asprimary particles in the solvent. Accordingly, the clarity of thecatalyst solution can be enhanced.

Also, the catalyst composition contains a resin and catalyst particlesdescribed above.

As the resin, the same resins as those listed in the second embodimentcan be used. These resins can be used singly or in a combination of twoor more.

It is also possible to select the catalyst particles and the resin suchthat the solubility parameters (SP values) thereof satisfy apredetermined relationship.

Specifically, the catalyst particles and the resin are selected so as toattain a predetermined SP difference (ΔSP, specifically, the absolutevalue of the difference between the solubility parameter of resin(SP_(RESIN) value) and the solubility parameter of catalyst particles(SP_(PARTICLE) value)).

Among the resins listed above, in the case where excellent mechanicalstrength needs to be imparted to the catalyst molded article molded froma catalyst composition, a highly oriented resin having high orientationis preferable. As the highly oriented resin, the same highly orientedresins as those listed in the second embodiment can be used. Also, theresin has, for example, a hydrophilic group such as a carboxyl group ora hydroxyl group, a hydrophobic group such as a hydrocarbon group, andthe like.

In order to prepare a catalyst composition, first, a solvent and a resindescribed above are blended so as to dissolve the resin in the solventto prepare a resin solution. After that, the resin solution is blendedwith catalyst particles, and the resulting mixture is stirred to preparea catalyst composition (first preparation method).

The proportion of resin relative to the resin solution is the same asthose shown in the second embodiment.

The proportion of the catalyst particles is, for example, 1 to 1000parts by mass, preferably 5 to 500 parts by mass and more preferably 10to 300 parts by mass per 100 parts by mass of the solids content (resin)of the resin solution. The proportion of the catalyst particles is also,for example, 0.1 to 300 parts by mass, preferably 1 to 200 parts by massand more preferably 3 to 100 parts by mass per 100 parts by mass of thetotal amount of the resin solution (the total amount of the resin andthe solvent).

Also, the catalyst composition can also be prepared by, first, preparinga catalyst solution described above, and then blending the catalystsolution with a resin and stirring the resulting mixture (secondpreparation method).

In the catalyst solution, the catalyst particles are dispersed asprimary particles in the solvent.

The proportion of resin is, for example, 10 to 10000 parts by mass,preferably 20 to 2000 parts by mass and more preferably 40 to 1000 partsby mass per 100 parts by mass of the solids content (catalyst particle)of the catalyst solution.

Furthermore, the catalyst composition can also be prepared by, forexample, blending a solvent, catalyst particles and a resinsimultaneously and stirring the resulting mixture (third preparationmethod).

The proportions of respective components per 100 parts by mass of thetotal amount of the catalyst composition are as follows: the proportionof the catalyst particles is, for example, 0.1 to 50 parts by mass,preferably 1 to 40 parts by mass and more preferably 3 to 30 parts bymass; and the proportion of resin is, 40 parts by mass or less,preferably 35 parts by mass or less, more preferably 30 parts by mass orless, and usually 1 part by mass or greater. The proportion of thesolvent is the remainder obtained by excluding the catalyst particlesand the resin from the catalyst composition.

Also, the catalyst composition can also be prepared by, first, preparinga resin solution and a catalyst solution in a separate manner and thenblending and stirring the resin solution and the catalyst solution(fourth preparation method).

The proportion of resin in the resin solution is the same as those shownin the first preparation method described above.

The proportion of the catalyst particles in the catalyst solution is thesame as those shown in the preparation method for a catalyst solutiondescribed above.

The resin solution and the catalyst solution are blended such that theproportion of resin relative to the catalyst particles in terms of massis, for example, 99:1 to 10:90, preferably 95:5 to 20:80 and morepreferably 90:10 to 30:70.

Furthermore, the catalyst composition can also be prepared without theuse of a solvent by, for example, melting a resin by application of heatand blending the resin with catalyst particles (fifth preparationmethod).

The thus-prepared catalyst composition is a melt of the catalystcomposition without a solvent.

The heating temperature is, in the case where the resin is athermoplastic resin, greater than or equal to the melting temperature ofthe resin, specifically, 200 to 350° C. In the case where the resin is athermosetting resin, the heating temperature is a temperature at whichthe resin is B-staged, for example, 85 to 140° C.

The proportion of resin relative to the catalyst particles in terms ofmass is, for example, 99:1 to 10:90, preferably 95:5 to 20:80 and morepreferably 90:10 to 30:70.

In the catalyst composition obtained by any of the above-describedpreparation methods, the catalyst particles are uniformly dispersed inthe resin. Specifically, in the catalyst composition, the catalystparticles are dispersed as primary particles in the resin (withoutsubstantial coagulation).

After that, the obtained catalyst composition is applied to, forexample, a known support plate to form a coating, and the coating isdried, whereby a catalyst molded article as a film is molded.

The catalyst composition is applied by using, for example, a knownapplication method such as spin coating or bar coating. Simultaneouslywith or immediately after application of the catalyst composition, thesolvent is removed by volatilization. If necessary, the solvent can bedried by application of heat after application of the catalystcomposition.

The thickness of the obtained film can be set as appropriate accordingto the use and purpose, and the thickness is, for example, 0.1 to 2000μm, preferably 0.1 to 1000 μm and more preferably 0.1 to 500 μm.

The catalyst molded article as a film can also be molded by a meltmolding method in which the catalyst composition is extruded by anextruding machine or the like.

The catalyst molded article can also be molded as a block (mass) byinjecting the catalyst composition into a metal mold or the like andthereafter subjecting the resultant to, for example, heat molding suchas heat pressing.

The catalyst molded article is formed of the catalyst composition inwhich the catalyst particles are dispersed in the resin, and theinorganic particles cannot easily come into direct contact with theresin due to the configuration based on the steric hindrance of theorganic group of the catalyst particles. Accordingly, the catalystmolded article can, while suppressing degradation of the resin, exert acatalytic action for a gas or a liquid.

Specifically, the catalyst molded article can exert a detoxificationaction, a deodorization action, a disinfectant (or in other words,antimicrobial or germicidal) action and a decomposition action fortoxins, odor (malodor), fungi and organic substances contained in a gassuch as the air by absorbing light, specifically, for example, lighthaving a wavelength of 1000 nm or less, preferably light having awavelength of 900 nm or less and more preferably light having awavelength of 800 nm or less. Furthermore, the catalyst molded articlecan exert a detoxification action, a disinfectant action, a dirtrepellent action and a decomposition action for toxins, fungi,excrements and organic substances contained in a liquid such as water.

As a result, the catalyst molded article can be used as a catalystmolded article having various catalytic actions (photocatalytic actions)such as a detoxification action, a deodorization action, a disinfectantaction, a dirt repellent action and a decomposition action whilemaintaining excellent durability.

Furthermore, in the catalyst molded article, the catalyst particles areuniformly dispersed, and thus clarity can be enhanced.

As a result, the catalyst molded article can be used in various opticalapplications and various construction material applications whereclarity is required.

Specifically, the catalyst molded article can be used as, in the casewhere it is molded as a film, for example, an optical film for use in animage display apparatus (liquid crystal display, organicelectroluminescent apparatus or the like) such as a polarizing film, aphase difference film, a brightness enhancing film, a viewing angleenhancing film, a high-refractive index film or a light diffusing film.

The catalyst molded article can also be used as, in the case where it ismolded as a film, for example, a construction material (construction)film such as an ultraviolet absorbing film, a dirt repellent film, anantimicrobial film, a deodorizing film, a super-hydrophilic film, agermicidal film, a detoxification film or a chemical substancedecomposing film.

Fourth Embodiment

Embodiment corresponding to the inventions of a resin molded article anda producing method therefor, which are included in the fourth group ofinventions

The resin molded article of the present invention can be obtained byremoving organic-inorganic composite particles from aparticle-containing resin molded article containing a resin and theorganic-inorganic composite particles.

The resin is a matrix component forming the resin molded article and canbe, for example, a thermosetting resin, a thermoplastic resin or thelike. Examples of the thermosetting resin and the thermoplastic resininclude the same thermosetting resins and thermoplastic resins as thoselisted in the second embodiment. These resins can be used singly or in acombination of two or more.

In the case where excellent mechanical strength and excellent clarityneeds to be imparted to the particle-containing resin molded articlethat is molded from a particle-containing resin composition (describedlater), the resin is preferably a polyester resin, a thermoplasticpolyimide resin, a polyetherimide resin or the like.

Also, the resin preferably has a functional group. Examples of thefunctional group include hydrophilic groups such as a carboxyl group anda hydroxyl group; hydrophobic groups such as a hydrocarbon group; andthe like.

Also, the resin has a refractive index for light having a wavelength of633 nm of, for example, greater than 1 and 3 or less, preferably 1.2 to2.5, and more preferably 1.3 to 2.0. The refractive index is measuredby, for example, a refractometer.

Also, the resin has a reflectance for light having a wavelength of 550nm of, for example, 1 to 10%, preferably 2 to 9% and more preferably 3to 8%. The reflectance is measured by, for example, a spectrophotometer.

Also, the resin has a dielectric constant of, for example, 1.5 to 1000,preferably 2 to 100 and more preferably 2 to 10. The dielectric constantis measured by, for example, an automatic dielectric loss measurementapparatus at a frequency of 1 MHz.

The organic-inorganic composite particles are particles that can bedispersed as primary particles in a solvent (described later) and/or aresin and extracted from the resin with an extraction solvent, andcontain inorganic particles and an organic group that binds to thesurface of the inorganic particles.

Specifically, the organic-inorganic composite particles are obtained bysurface-treating an inorganic material form inorganic particles with anorganic compound. The organic-inorganic composite particles can be usedsingly or in a combination of two or more.

The inorganic material form inorganic particles can be a metal composedof a metal element such as a main group element or a transition element,a nonmetal composed of a nonmetal element such as boron or silicon, aninorganic compound and/or a complex containing a metal element and/or anonmetal.

Examples of the metal element and the nonmetal element include elementsthat are located on the left side and the lower side of a border linethat is assumed to pass through boron (B) of the IIIB group, silicon(Si) of the IVB group, arsenic (As) of the VB group, tellurium (Te) ofthe VIB group and astatine (At) of the VIIB group on the long-formperiodic table (IUPAC, 1989), as well as the elements that are locatedon the border line. Specific examples thereof include the group Ielements (alkali metals) such as Li, Na, K, Rb and Cs; the group IIelements (alkaline earth metals) such as Be, Mg, Ca, Sr, Ba and Ra; andthe same elements as those listed in the second embodiment.

Examples of the inorganic compound include the same inorganic compoundsas those listed in the second embodiment.

Preferable examples of the inorganic compound include an oxide, acarbonate, a sulfate and the like.

The oxide can be, for example, a metal oxide. Preferable examplesinclude titanium oxide (titanium dioxide, titanium oxide (IV), titania:TiO₂), cerium oxide (cerium dioxide, cerium oxide (IV), ceria: CeO₂),zinc oxide (zinc oxide (II), flowers of zinc or zinc white, ZnO) and thelike.

The oxides can be used singly or in a combination of two or more.

In the carbonate, the element that combines with carbonic acid can be,for example, an alkali metal, an alkaline earth metal or the like. Thealkali metal and the alkaline earth metal can be the same alkali metalsand alkaline earth metals as those listed above.

The element that combines with carbonic acid is preferably an alkalineearth metal.

Specifically, the carbonate is preferably a carbonate containing analkaline earth metal, and examples of such a carbonate include berylliumcarbonate, magnesium carbonate, calcium carbonate, strontium carbonate,barium carbonate, radium carbonate and the like. These carbonates can beused singly or in a combination of two or more.

The sulfate is a compound consisting of a sulfate ion (SO₄ ²⁻) and ametal cation (more specifically, a compound formed by substitution ofthe hydrogen atoms of sulfuric acid (H₂SO₄) with a metal), and the metalcontained in the sulfate can be, for example, an alkali metal, analkaline earth metal or the like. The alkali metal and the alkalineearth metal can be the same alkali metals and alkaline earth metals asthose listed above.

The metal is preferably an alkaline earth metal.

Specifically, the sulfate is preferably a sulfate containing an alkalineearth metal, and examples of such a sulfate include beryllium sulfate,magnesium sulfate, calcium sulfate, strontium sulfate, barium sulfate,radium sulfate and the like. Barium sulfate is preferable.

The sulfates can be used singly or in a combination of two or more.

The inorganic materials listed above can be used singly or in acombination of two or more.

The organic compound is, for example, an organic group-introducingcompound that introduces (disposes) an organic group on the surface ofinorganic particles. Specifically, the organic compound contains abinding group capable of binding to the surface of inorganic particlesand an organic group.

The binding group may be selected as appropriate according to the typeof inorganic particles, and examples thereof include functional groupssuch as carboxyl group, phosphoric acid group (—PO(OH)₂, phosphonogroup), amino group, sulfo group, hydroxyl group, thiol group, epoxygroup, isocyanate group (cyano group), nitro group, azo group, silyloxygroup, imino group, aldehyde group (acyl group), nitrile group, vinylgroup (polymerizable group) and the like. Preferable examples includecarboxyl group, phosphoric acid group, amino group, sulfo group,hydroxyl group, thiol group, epoxy group, azo group, vinyl group, andthe like. More preferable examples include carboxyl group and phosphoricacid group.

The carboxyl group includes a carboxylic acid ester group (carboxy estergroup).

The phosphoric acid group includes a phosphoric acid ester group(phosphonate group).

One or more of these binding groups are contained in the organiccompound. Specifically, the binding group is bound to a terminal or aside chain of the organic group.

The binding group is selected as appropriate according to the type ofinorganic particles. Specifically, when the inorganic particles containcerium oxide, strontium carbonate and/or barium sulfate, for example,carboxyl group is selected. When the inorganic particles containtitanium oxide and/or zinc oxide, for example, a phosphoric acid groupis selected.

The organic group includes, for example, a hydrocarbon group such as analiphatic group, an alicyclic group, an araliphatic group or an aromaticgroup, or the like.

Examples of the hydrocarbon groups include the same hydrocarbon groupsas those listed in the second embodiment.

The organic group is a hydrophobic group for imparting hydrophobicity tothe surface of inorganic particles.

Accordingly, the organic compounds containing a hydrophobic groupdescribed above are used as hydrophobic organic compounds forhydrophobic treatment of inorganic particles. Specific examples of suchhydrophobic organic compounds include the same hydrophobic organiccompounds as those listed in the second embodiment.

Alternatively, the organic compound can also be used as a hydrophilicorganic compound for hydrophilic treatment of inorganic particles. Inthis case, the organic group contained in the hydrophilic organiccompound includes any of the above hydrocarbon groups and a hydrophilicgroup that binds to the hydrocarbon group.

Specifically, in the hydrophilic organic compound, the hydrophilic groupis bound to a terminal (the terminal (the other terminal) opposite theterminal that is bound to the binding group (one terminal)) or a sidechain of the hydrocarbon group.

The hydrophilic group is a functional group having a polarity (or inother words, polar group), and examples thereof include the samefunctional groups as those listed in the second embodiment. One or moreof the hydrophilic groups are contained in the hydrophilic organiccompound.

Specific examples of the organic compound containing a hydrophilic groupinclude the same carboxyl group-containing organic compounds, hydroxylgroup-containing organic compounds, phosphoric acid group-containingorganic compounds, amino group-containing organic compounds, sulfogroup-containing organic compounds, carbonyl group-containing organiccompounds, cyano group-containing organic compounds, nitrogroup-containing organic compounds, aldehyde group-containing organiccompounds and thiol group-containing organic compounds as those listedin the second embodiment.

The same or mutually different organic groups may be used.

In the case where mutually different organic groups are used, or inother words, the organic group contains a plurality of mutuallydifferent types of organic groups, a plurality of homologous organicgroups and/or a plurality of heterologous organic groups are contained.

Examples of the homologous organic groups include the same combinationsas those listed in the second embodiment.

A preferable example of the homologous organic groups is a combinationof a plurality of aliphatic groups, a more preferable example is acombination of a plurality of saturated aliphatic groups, and aparticularly preferable example is a combination of a saturatedaliphatic group having less than 10 carbon atoms and a saturatedaliphatic group having 10 or more carbon atoms. Specific examplesinclude a combination of hexyl and decyl and a combination of octyl anddecyl.

When the organic group contains a plurality of homologous organicgroups, a plurality of organic groups having different sizes (lengthsor/and dimensions, or in other words, the number of carbon atoms) arecontained in the organic group. Accordingly, in a space between adjacentlarger organic groups, a resin molecule enters a gap (pocket) formed inaccordance with the smaller organic group, and the interaction betweenthe larger organic group and the resin molecule can be enhanced. As aresult, the dispersibility of the organic-inorganic composite particlescan be enhanced.

Examples of the heterologous organic groups include the samecombinations as those listed in the second embodiment.

As long as the organic group contains a plurality of heterologousorganic groups, when the resin is prepared as a mixture of a pluralityof resin components, the organic group can exert excellent compatibilitywith the resin molecules of the respective resin components havingexcellent compatibility with the organic groups of the respectivegroups. Accordingly, the interaction between the organic groups and theresin molecules of the resin components can be enhanced. As a result,the dispersibility of the organic-inorganic composite particles can beenhanced.

The organic groups are present on the surface of inorganic particles inthe organic-inorganic composite particles. Specifically, the organicgroups are bound to the surface of inorganic particles via a bindinggroup. Also, the organic groups extend from the surface of inorganicparticles toward the outside of the inorganic particles via a bindinggroup.

The organic-inorganic composite particles are prepared by subjecting aninorganic material and an organic compound to a reaction treatment,preferably to a high temperature treatment.

The high temperature treatment is carried out in a solvent. As thesolvent, for example, water and any above-listed organic compounds canbe used.

Specifically, the organic-inorganic composite particles are obtained bysubjecting an inorganic material and an organic compound to a hightemperature treatment in water under high pressure conditions(hydrothermal synthesis: hydrothermal reaction), or subjecting aninorganic material to a high temperature treatment in an organiccompound (high temperature treatment in an organic compound). In otherwords, the organic-inorganic composite particles are obtained bysurface-treating the surface of inorganic particles formed by aninorganic material with (or in the presence of) an organic compound.

In the hydrothermal synthesis, for example, the inorganic material andthe organic compound are reacted under high-temperature andhigh-pressure conditions in the presence of water (first hydrothermalsynthesis).

The inorganic material subjected to the first hydrothermal synthesis ispreferably an inorganic compound, and more preferably a carbonate or asulfate.

Specifically, first, a reaction system is prepared underhigh-temperature and high-pressure conditions by placing an inorganicmaterial, an organic compound and water in a pressure-resistant airtightcontainer and heating them.

The proportions of respective components per 100 parts by mass of theinorganic material are as follows: the proportion of the organiccompound is, for example, 1 to 1500 parts by mass, preferably 5 to 500parts by mass and more preferably 5 to 250 parts by mass; and theproportion of water is, for example, 50 to 8000 parts by mass,preferably 80 to 6600 parts by mass and more preferably 100 to 4500parts by mass.

The density of the organic compound is usually 0.8 to 1.1 g/mL, and thusthe proportion of the organic compound is, for example, 1 to 1500 mL,preferably 5 to 500 mL and more preferably 5 to 250 mL per 100 g of theinorganic material.

Also, the number of moles of the organic compound can be, for example,0.01 to 1000 mol, preferably 0.02 to 50 mol, and more preferably 0.1 to10 mol per mol of the inorganic material.

In the case where the organic compound contain a plurality of (forexample, two) different types of organic groups, specifically, the molarratio between an organic compound containing one type of organic groupand an organic compound containing the other type of organic group is,for example, 10:90 to 99.9:0.1, and preferably 20:80 to 99:1.

Also, the density of water is usually approximately 1 g/mL, and thus theproportion of water is, for example, 50 to 8000 mL, preferably 80 to6600 mL, and more preferably 100 to 4500 mL per 100 g of the inorganicmaterial.

The reaction conditions for the hydrothermal reaction are the samereaction conditions as those shown in the second embodiment.

In the above reaction, if necessary, an aqueous pH adjusting solutionsuch as an aqueous ammonia solution or an aqueous solution of potassiumhydroxide can be added in an appropriate proportion.

The reaction product obtained by the above reaction includes aprecipitate that mostly precipitates in water and a deposit that adheresto the inner wall of the airtight container.

The precipitate is obtained by, for example, sedimentation separation inwhich the reaction product is settled by gravity or a centrifugal field.Preferably, the precipitate is obtained as a precipitate of the reactionproduct by centrifugal sedimentation (centrifugal separation) in whichthe reaction product is settled by a centrifugal field.

The deposit is recovered by, for example, a scraper (spatula) or thelike.

The reaction product can also be recovered (separated) by adding asolvent to wash away an unreacted organic compound (or in other words,dissolving the organic compound in the solvent) and thereafter removingthe solvent (recovering step).

The solvent can be, for example, an alcohol (hydroxyl group-containingaliphatic hydrocarbon) such as methanol, ethanol, propanol orisopropanol; a ketone (carbonyl group-containing aliphatic hydrocarbon)such as acetone, methyl ethyl ketone, cyclohexanone or cyclopentanone;an aliphatic hydrocarbon such as pentane, hexane or heptane; ahalogenated aliphatic hydrocarbon such as dichloromethane, chloroform ortrichloroethane; a halogenated aromatic hydrocarbon such aschlorobenzene or dichlorobenzene; an ether such as tetrahydrofuran; anaromatic hydrocarbon such as benzene, toluene or xylene; an aqueous pHadjusting solution described above; or the like.

The washed reaction product is separated from the solvent (supernatantliquid) by, for example, filtration, decantation or the like, andrecovered. After that, the reaction product is dried by, for example,application of heat, an air stream or the like if necessary.

In this manner, the organic-inorganic composite particles containinginorganic particles and an organic group that binds to the surface ofthe inorganic particles are obtained.

Note that in the first hydrothermal synthesis, the inorganic materialbefore reaction and the inorganic particles after reaction have the samecomposition.

Alternatively, the organic-inorganic composite particles containinginorganic particles formed of an inorganic substance that is differentfrom the inorganic material serving as a starting material can also beobtained by subjecting an inorganic material (starting material) and anorganic compound to a hydrothermal synthesis (second hydrothermalsynthesis).

The inorganic material subjected to the second hydrothermal synthesiscan be, for example, a hydroxide, an acetate, a complex or the like.

In the hydroxide, the element (element that constitutes a cation thatcombines with a hydroxyl ion (OH⁻)) contained in the hydroxide can bethe same as the element that combines with oxygen in an oxide listedabove.

Specifically, the hydroxide can be, for example, titanium hydroxide(Ti(OH)₄) or cerium hydroxide (Ce(OH)₄).

In the acetate, the element contained in the acetate that combine withan acetic acid ion (CH₃COO⁻) can be a group IIB element, preferably Zn,Cd or the like.

Specifically, the acetate is preferably an acetate containing a groupIIB element, and specific examples of such an acetate include zincacetate, cadmium acetate and the like. These acetates can be used singlyor in a combination of two or more.

The complex contains a central atom and/or a central ion and a ligandthat coordinates thereto.

Examples of the central atom include the same metal elements as thoselisted above. A group IVA element is preferable, and Ti is morepreferable.

Examples of the central ion include cations of the metal elements listedabove.

Examples of the ligand include coordinating compounds such as carboxylicacid, hydroxycarboxylic acid and acetylacetone; coordinating ions suchas cations and hydroxide ions in the above coordinating compounds; andthe like.

Examples of the carboxylic acid include dicarboxylic acids such asoxalic acid, succinic acid and phthalic acid, and the like.

Examples of the hydroxycarboxylic acid include monohydroxymonocarboxylicacid (specifically, α-monohydroxycarboxylic acids) such as2-hydroxyoctanoic acid, lactic acid and glycolic acid;monohydroxydicarboxylic acids such as malic acid;monohydroxytricarboxylic acids such as citric acid; and the like.

The coordination number is, for example, 1 to 6 and preferably 1 to 3.

The complex can be obtained by preparation from a metal element and aligand described above.

The complex can also be formed (prepared) as a salt and/or a hydrate.Examples of the salt include salts with cations such as ammonium ions.

As the organic compound, for example, the same organic compounds asthose that can be used in the first hydrothermal synthesis describedabove can be used.

In the second hydrothermal synthesis, the inorganic material and theorganic compound are reacted under high-temperature and high-pressureconditions in the presence of water.

The proportions of respective components per 100 parts by mass of theinorganic compound are as follows: the proportion of the organiccompound is, for example, 1 to 1500 parts by mass, preferably 5 to 500parts by mass and more preferably 5 to 250 parts by mass; and theproportion of water is, for example, 50 to 8000 parts by mass,preferably 80 to 6600 parts by mass and more preferably 80 to 4500 partsby mass.

Also, the proportion of the organic compound is, for example, 0.9 to1880 mL, preferably 4.5 to 630 mL and more preferably 4.5 to 320 mL per100 g of the hydroxide, and the number of moles of the organic compoundcan be, for example, 0.01 to 10000 mol and preferably 0.1 to 10 mol permol of the hydroxide.

Also, the proportion of water is, for example, 50 to 8000 mL, preferably80 to 6600 mL and more preferably 100 to 4500 mL per 100 g of thehydroxide.

The reaction conditions for the second hydrothermal synthesis are thesame as those for the first hydrothermal synthesis described above.

In this manner, the organic-inorganic composite particles containinginorganic particles formed of an inorganic substance having a differentcomposition as that of the starting inorganic material and an organicgroup that binds to the surface of the inorganic particles are obtained.

In the high temperature treatment in an organic compound, an inorganicmaterial and an organic compound are blended and heated, for example,under normal atmospheric pressure conditions. The organic compound issubjected to the high temperature treatment while serving as an organicgroup-introducing compound as well as a solvent for dispersing ordissolving the inorganic material.

The proportion of the organic compound is, for example, 10 to 10000parts by mass and preferably 100 to 1000 parts by mass per 100 parts bymass of the inorganic material. The proportion of the organic compoundin terms of volume is, for example, 10 to 10000 mL and preferably 100 to1000 mL per 100 g of the inorganic material.

The heating temperature is the same as those shown in the secondembodiment. The heating time is the same as those shown in the secondembodiment.

There is no particular limitation on the configuration of theorganic-inorganic composite particles (primary particles) obtained inthe above-described manner, and for example the organic-inorganiccomposite particles may be anisotropic or isotropic, with an averageparticle size (average maximum length in the case where they areanisotropic) of, for example, 400 nm or less, preferably 200 nm or lessand more preferably 100 nm or less, and usually for example, 1 nm orgreater and preferably 3 nm or greater.

As will be described in detail in the examples given below, the averageparticle size of the organic-inorganic composite particles is determinedby measurement by dynamic light scattering (DLS) and/or calculated froma transmission electron microscopic (TEM) or scanning electronmicroscopic (SEM) image analysis.

If the average particle size of the organic-inorganic compositeparticles exceeds the above range, the micropores (described later) willbe too large, and the clarity of the resin molded article (porous film,described later) will be low. Also, the organic-inorganic compositeparticles may be crushed when mixed with the resin or the like. If theaverage particle size exceeds the above range, the organic-inorganiccomposite particles may be crushed when mixed with the resin or thelike.

If, on the other hand, the average particle size of theorganic-inorganic composite particles is below the above range, theproportion of the volume of the organic group relative to the surface ofthe organic-inorganic composite particles will be high, and the functionof the inorganic particles is unlikely to be obtained.

The organic-inorganic composite particles thus obtained are unlikely tocoagulate in a dry state, and even if the organic-inorganic compositeparticles appear coagulated in a dry state, the coagulation betweeninorganic particles is prevented in a particle-containing resincomposition and a particle-containing resin molded article.

In other words, the organic-inorganic composite particles have at leasta configuration that does not allow the inorganic particles to contactwith each other by steric hindrance of the organic group.

The organic-inorganic composite particles are also particles that can beeasily re-dispersed by simply adding a solvent (described later) even ifthey are once dried.

In the organic-inorganic composite particles, the proportion of thesurface area of the organic group relative to the surface area of theinorganic particles, or in other words, the surface coverage by theorganic group in the organic-inorganic composite particles (=(surfacearea of organic group/surface area of inorganic particles)×100) is, forexample, 30% or greater and preferably 60% or greater and usually 200%or less.

The surface coverage is determined by the same method as that describedin the second embodiment.

In the case where at least the surface coverage is high and the organicgroup of the organic-inorganic composite particles has a lengthsufficient to cancel the electric charge of the inorganic particles, thetype of solvent (medium) for dispersing the organic-inorganic compositeparticles can be controlled (designed or managed) according to the typeof organic group.

The organic-inorganic composite particles obtained in theabove-described manner can be subjected to wet classification.

As the wet classification, the same wet classification as that shown inthe second embodiment is used.

With the wet classification, organic-inorganic composite particleshaving a small average particles size can be obtained.

With the wet classification, the average particle size of the resultingorganic-inorganic composite particles can be adjusted to, for example,400 nm or less, preferably 200 nm or less and more preferably 100 nm orless, and usually, for example, 0.1 nm or greater, and preferably 0.3 nmor greater.

It is also possible to select the resin and the organic-inorganiccomposite particles such that the solubility parameters (SP values)thereof satisfy a predetermined relationship.

Specifically, the resin and the organic-inorganic composite particlesare selected so as to attain a predetermined SP difference (ΔSP,specifically, the absolute value of the difference between thesolubility parameter of resin (SP_(RESIN) value) and the solubilityparameter of organic-inorganic composite particles (SP_(PARTICLE)value)).

Preferable hydrophilic groups included in both the functional group andthe organic group are a carboxyl group and a hydroxyl group, andpreferable hydrophobic groups included in both the functional group andthe organic group are a hydrocarbon group and the like. The affinitybetween the organic-inorganic composite particles and the resin can beenhanced as a result of both the functional group and the organic grouphaving any of the above groups having the same property (hydrophilicityor hydrophobicity).

In order to obtain the resin molded article of the present invention,first, a particle-containing resin composition is prepared by blending aresin and organic-inorganic composite particles described above.

In the prepared particle-containing resin composition, the existing(dispersed) state of organic-inorganic composite particles in theparticle-containing resin composition varies depending on thecomposition of organic group contained in the organic-inorganiccomposite particles. Accordingly, the existing (dispersed) state oforganic-inorganic composite particles in the particle-containing resincomposition is not limited to the proportion of resin toorganic-inorganic composite particles (described later).

To prepare a particle-containing resin composition, the same solutionpreparation as that described in the second embodiment is used.

As the solvent, the same solvents as those listed in the secondembodiment can be used. These solvents can be used singly or in acombination of two or more. The solvent is preferably a halogenatedaliphatic hydrocarbon.

Specifically, in order to prepare a particle-containing resincomposition, first, a solvent and a resin described above are blended soas to dissolve the resin in the solvent to prepare a resin solution.After that, the resin solution is blended with organic-inorganiccomposite particles, and the resulting mixture is stirred to prepare aparticle-containing resin composition (first preparation method).

The proportion of resin relative to the resin solution is the same asthose (in terms of mass, volume, mol, and the like) shown in the secondembodiment.

The proportion of the organic-inorganic composite particles is, forexample, 1 to 5000 parts by mass, preferably 5 to 3000 parts by mass andmore preferably 10 to 300 parts by mass per 100 parts by mass of thesolids content (resin) of the resin solution.

In particular, for example, in order to disperse (described later) theorganic-inorganic composite particles as primary particles in the resin,the proportion of the organic-inorganic composite particles is set to berelatively low (or in other words, the organic-inorganic compositeparticles are blended at a low concentration). Specifically, theproportion of the organic-inorganic composite particles is set to, forexample, less than 1000 parts by mass, preferably 500 parts by mass orless, and more preferably 300 parts by mass or less, and for example, 1part by mass or greater per 100 parts by mass of the solids content(resin) of the resin solution.

On the other hand, in order to cause the organic-inorganic compositeparticles to phase separate (described later) from the resin phase, theproportion of the organic-inorganic composite particles is set to berelatively high (or in other words, the organic-inorganic compositeparticles are blended at a high concentration). In particular, in orderto form the particle-containing resin molded article so as to have abicontinuous structure (described later), the proportion of theorganic-inorganic composite particles is set to, for example, 5 parts bymass or greater, preferably 10 parts by mass or greater, more preferably20 parts by mass or greater and usually, for example, 5000 parts by massor less per 100 parts by mass of the solids content (resin) of the resinsolution.

Also, in order to form the particle-containing resin molded article soas to have a two-phase separated structure (sea-island structure,described later), the proportion of the organic-inorganic compositeparticles is, for example, 50 to 500% and preferably 80 to 400% of thatwhen the particle-containing resin molded article is formed so as tohave a bicontinuous structure.

Also, the particle-containing resin composition can also be prepared byblending a solvent and organic-inorganic composite particles to dispersethe organic-inorganic composite particles in the solvent to prepare aparticle dispersion, and then blending the particle dispersion with aresin and stirring the resulting mixture (second preparation method).

In the particle dispersion, the organic-inorganic composite particlesare dispersed as primary particles in the solvent.

The proportion of the organic-inorganic composite particles is, forexample, 0.1 to 80 parts by mass, preferably 0.2 to 60 parts by mass andmore preferably 0.5 to 50 parts by mass per 100 parts by mass of theparticle dispersion.

The proportion of resin relative to the solids content(organic-inorganic composite particles) of the particle dispersion isthe same as those (in terms of mass, volume, mol, and the like) shown inthe second embodiment.

In particular, in order to disperse (described later) theorganic-inorganic composite particles as primary particles in the resin,the proportion of resin is set to be relatively high (or in other words,the resin is blended at a high concentration). Specifically, theproportion of resin is, for example, 1 part by mass or greater,preferably 10 parts by mass or greater, more preferably 20 parts by massor greater, particularly preferably 40 parts by mass or greater, and forexample, 10000 parts by mass or less per 100 parts by mass of the solidscontent (organic-inorganic composite particles) of the particledispersion.

On the other hand, in order to cause the organic-inorganic compositeparticles to phase separate (described later) from the resin phase, theproportion of resin is set to be relatively low (or in other words, theresin is blended at a low concentration). Specifically, in order to formthe particle-containing resin molded article so as to have abicontinuous structure (described later), the proportion of resin is setto, for example, less than 2000 parts by mass, preferably 1000 parts bymass or less, more preferably 500 parts by mass or less, and forexample, 1 part by mass or greater per 100 parts by mass of the solidscontent (organic-inorganic composite particles) of the particledispersion.

Also, in order to form the particle-containing resin molded article soas to have a two-phase separated structure (sea-island structure), theproportion of resin is, for example, 10 to 300% and preferably 20 to200% of that when the particle-containing resin molded article is formedso as to have a bicontinuous structure.

Furthermore, the particle-containing resin composition can also beprepared by, for example, blending a solvent, organic-inorganiccomposite particles and a resin simultaneously and stirring theresulting mixture (third preparation method).

The proportions of respective components per 100 parts by mass of thetotal amount of the organic-inorganic composite particles and the resinare as follows: the proportion of the organic-inorganic compositeparticles is, for example, 0.1 to 99.9 parts by mass, preferably 1 to 99parts by mass and more preferably 3 to 95 parts by mass; and theproportion of resin is 0.1 to 99.9 parts by mass, preferably 1 to 99parts by mass and more preferably 5 to 97 parts by mass.

Also, the proportion of the solvent is, for example, 1 to 10000 parts bymass and preferably 10 to 5000 parts by mass per 100 parts by mass ofthe total amount of the organic-inorganic composite particles and theresin.

In particular, in order to disperse (described later) theorganic-inorganic composite particles as primary particles in the resin,the proportion of the organic-inorganic composite particles is set to berelatively low (or in other words, the organic-inorganic compositeparticles are blended at a low concentration). Specifically, theproportion of the organic-inorganic composite particles is set to, forexample, less than 99 parts by mass, preferably 90 parts by mass orless, more preferably 80 parts by mass or less, particularly preferably70 parts by mass or less and for example, 0.1 parts by mass or greaterper 100 parts by mass of the total amount of the organic-inorganiccomposite particles and the resin.

On the other hand, in order to cause the organic-inorganic compositeparticles to phase separate from the resin phase, the proportion of theorganic-inorganic composite particles is set to be relatively high (orin other words, the organic-inorganic composite particles are blended ata high concentration). In particular, in order to form theparticle-containing resin molded article so as to have a bicontinuousstructure, the proportion of the organic-inorganic composite particlesis set to, for example, 5 parts by mass or greater, preferably 10 partsby mass or greater, more preferably 20 parts by mass or greater and forexample, 99 parts by mass or less per 100 parts by mass of the totalamount of the organic-inorganic composite particles and the resin.

Also, in order to form the particle-containing resin molded article soas to have a two-phase separated structure (sea-island structure), theproportion of the organic-inorganic composite particles is, for example,50 to 500% and preferably 80 to 400% of that when theparticle-containing resin molded article is formed so as to have abicontinuous structure.

Also, the particle-containing resin composition can also be prepared by,first, preparing a resin solution and a particle dispersion in aseparate manner, and then blending and stirring the resin solution andthe particle dispersion (fourth preparation method).

The proportion of resin in the resin solution is the same as those shownin the first preparation method described above.

The proportion of the organic-inorganic composite particles in theparticle dispersion is the same as those shown in the second preparationmethod described above.

The resin solution and the particle dispersion are blended such that theproportion of the organic-inorganic composite particles is, for example,0.1 to 99.9 parts by mass, preferably 1 to 99 parts by mass and morepreferably 3 to 95 parts by mass per 100 parts by mass of the totalamount of the organic-inorganic composite particles and the resin.

In particular, in order to disperse (described later) theorganic-inorganic composite particles as primary particles in the resin,the resin solution and the particle dispersion are blended such that theproportion of the organic-inorganic composite particles is relativelylow (or in other words, the concentration of the organic-inorganiccomposite particles is low). Specifically, the resin solution and theparticle dispersion are blended such that the proportion of theorganic-inorganic composite particles is, for example, less than 99parts by mass, preferably 90 parts by mass or less, more preferably 80parts by mass or less, particularly preferably 70 parts by mass or lessand for example, 0.1 parts by mass or greater per 100 parts by mass ofthe total amount of the organic-inorganic composite particles and theresin.

On the other hand, in order to cause the organic-inorganic compositeparticles to phase separate (described later) from the resin phase, theresin solution and the particle dispersion are blended such that theproportion of the organic-inorganic composite particles is relativelyhigh (or in other words, the concentration of the organic-inorganiccomposite particles is high). In particular, in order to form theparticle-containing resin molded article so as to have a bicontinuousstructure, the resin solution and the particle dispersion are blendedsuch that the proportion of the organic-inorganic composite particlesis, for example, less than 99.9 parts by mass, preferably 99 parts bymass or less, more preferably 95 parts by mass or less, particularlypreferably 90 parts by mass or less, for example, 5 parts by mass orgreater, preferably 10 parts by mass or greater, and more preferably 20parts by mass or greater per 100 parts by mass of the total amount ofthe organic-inorganic composite particles and the resin.

Also, in order to form the particle-containing resin molded article soas to have a two-phase separated structure (sea-island structure), theproportion of the organic-inorganic composite particles is, for example,50 to 500% and preferably 80 to 400% of that when theparticle-containing resin molded article is formed so as to have abicontinuous structure.

Furthermore, the particle-containing resin composition can also beprepared by without the use of a solvent by, for example, melting aresin by application of heat and blending the resin withorganic-inorganic composite particles (fifth preparation method).

The thus-prepared particle-containing resin composition is a melt of theparticle-containing resin composition without a solvent.

The heating temperature is the same as those shown in the secondembodiment.

The proportion of resin is, for example, 1 to 90 parts by mass,preferably 5 to 80 parts by mass and more preferably 10 to 70 parts bymass per 100 parts by mass of the total amount of the resin and theorganic-inorganic composite particles.

In particular, in order to disperse (described later) theorganic-inorganic composite particles as primary particles in the resin,the proportion of the organic-inorganic composite particles is set to berelatively low (or in other words, the organic-inorganic compositeparticles are blended at a low concentration). Specifically, theproportion of the organic-inorganic composite particles is, for example,less than 99 parts by mass, preferably 90 parts by mass or less, morepreferably 80 parts by mass or less, particularly preferably 70 parts bymass or less, for example, 0.01 parts by mass or greater, preferably 0.1parts by mass or greater, and more preferably 1 part by mass or greaterper 100 parts by mass of the total amount of the resin and theorganic-inorganic composite particles.

On the other hand, in order to cause the organic-inorganic compositeparticles to phase separate (described later) from the resin, theproportion of the organic-inorganic composite particles is set to berelatively high (or in other words, the organic-inorganic compositeparticles are blended at a high concentration). In particular, in orderto form the particle-containing resin molded article so as to have abicontinuous structure, the proportion of the organic-inorganiccomposite particles is set to, for example, 5 parts by mass or greater,preferably 10 parts by mass or greater, more preferably 20 parts by massor greater and for example, 99 parts by mass or less per 100 parts bymass of the total amount of the organic-inorganic composite particlesand the resin.

Also, in order to form the particle-containing resin molded article soas to have a two-phase separated structure (sea-island structure), theproportion of the organic-inorganic composite particles is, for example,50 to 500% and preferably 80 to 400% of that when theparticle-containing resin molded article is formed so as to have abicontinuous structure.

The particle-containing resin composition obtained by any of theabove-described preparation methods has a configuration that does notallow the inorganic particles to contact with each other by sterichindrance of the organic group, and therefore coagulation of theinorganic particles is prevented.

Next, in order to obtain the resin molded article of the presentinvention, a particle-containing resin molded article is formed from theparticle-containing resin composition prepared above.

To form a particle-containing resin molded article, theparticle-containing resin composition is applied to, for example, asubstrate to form a coating, and the coating is dried, whereby aparticle-containing resin molded article as a film (particle-containingresin film) is molded. After that, the film is peeled off from thesubstrate.

The substrate is made of a material that is not dissolved in anextraction liquid, which will be described later. Specific examplesinclude polyester films such as a polyethylene terephthalate film (PET);olefin films such as a polyethylene film and a polypropylene film;polyvinyl chloride films; polyimide films; polyamide films such as anylon film; and synthetic resin films such as a rayon film. Otherexamples of the substrate include paper substrates such as fine qualitypaper, Japanese paper, kraft paper, glassine paper, synthetic paper andtop-coat paper. Furthermore, other examples of the substrate include aglass plate, a copper plate, an aluminum plate, and an inorganicsubstrate such as stainless steel (SUS).

The thickness of the substrate is, for example, 2 to 1500 μm.

The particle-containing resin composition is applied by using, forexample, a known application method such as spin coating or bar coating.Simultaneously with or immediately after application of theparticle-containing resin composition, the solvent is removed byvolatilization. If necessary, the solvent can be dried by application ofheat after application of the particle-containing resin composition.

The thickness of the obtained film can be set as appropriate accordingto the use and purpose, and the thickness is, for example, 0.1 to 2000μm, preferably 0.2 to 1000 μm and more preferably 0.3 to 500 μm.

The particle-containing resin molded article as a film can also bemolded by a melt molding method in which the particle-containing resincomposition is extruded by an extruding machine or the like.

The particle-containing resin molded article can also be molded as ablock (mass) by injecting the particle-containing resin composition intoa metal mold or the like and thereafter subjecting the resultant to, forexample, heat molding such as heat pressing,

In any of the particle-containing resin molded articles molded in theabove-described manner, the organic-inorganic composite particles aredispersed as primary particles in the resin in the case where theorganic-inorganic composite particles are blended at a lowconcentration. In other words, in the particle-containing resin moldedarticle, the organic-inorganic composite particles are prevented fromcoagulating and forming secondary particles.

On the other hand, in the case where the organic-inorganic compositeparticles are blended at a high concentration, the particle-containingresin molded article has a phase separated structure formed of a resinphase composed of resin and a particle phase composed oforganic-inorganic composite particles. The particle phase isphase-separated from the resin phase.

The phase separated structure can be, for example, a two-phase separatedstructure (sea-island structure) in which the particle phase isdispersed in the resin phase.

Also, the phase separated structure can be, for example, a bicontinuousphase separated structure in which the particle phase isthree-dimensionally continuous. In the bicontinuous phase separatedstructure, because the particle phase is three-dimensionally continuous,the organic-inorganic composite particles in the particle phase can beextracted continuously (described later).

Other examples of the phase separated structure include a honeycombstructure, a columnar structure and the like.

After that, the organic-inorganic composite particles are removed fromthe particle-containing resin molded article, whereby the resin moldedarticle of the present invention can be obtained.

In order to remove the organic-inorganic composite particles, forexample, an extraction method is used in which an extraction solvent isbrought into contact with the particle-containing resin molded article.With the extraction method, specifically, the particle-containing resinmolded article is immersed in an extraction liquid.

The extraction liquid can be, for example, a solvent that dissolvesorganic-inorganic composite particles and permeates through resinwithout corroding (damaging) the resin. Examples of such a solventinclude an acid and an alkali.

Examples of the acid include inorganic acids such as nitric acid,hydrochloric acid, sulfuric acid, carbonic acid and phosphoric acid;organic acids such as formic acid and acetic acid; and the like.

Examples of the alkali include inorganic alkalis such as sodiumhydroxide, potassium hydroxide; and organic alkalis such as ammonia.

An acid is preferable, and an inorganic acid is more preferable.

The extraction liquid can be, for example, diluted with a diluent suchas water, an alcohol (ethanol or the like), an aliphatic hydrocarbon(hexane or the like), and the concentration of the extraction liquid is,for example, 1 mass % or greater and less than 100 mass % of the totalmass of the extraction liquid and the diluent.

In the case where a solvent is used as the extraction liquid, regardlessof the level of the concentration of the organic-inorganic compositeparticles (or in other words, the structure of the organic-inorganiccomposite particles or particle phase in the particle-containing resinmolded article), the organic-inorganic composite particles can bedissolved. A solvent is preferably used particularly when in theparticle-containing resin molded article, the organic-inorganiccomposite particles are blended at a low concentration and theorganic-inorganic composite particles are dispersed as primary particlesin the resin. In this case, the solvent permeates through the resin andalso dissolves the organic-inorganic composite particles dispersed asprimary particles in the resin.

There is no particular limitation on the extraction liquid, and, forexample, it can be a dispersing medium that disperses organic-inorganiccomposite particles, does not corrode (damage) resin and does notpermeate through resin. Examples of the dispersing medium include thesame dispersing media as the solvents used in the washing step describedabove. Specific examples include water, an aqueous pH adjustingsolution, a hydroxyl group-containing aliphatic hydrocarbon, a carbonylgroup-containing aliphatic hydrocarbon, an aliphatic hydrocarbon, ahalogenated aliphatic hydrocarbon, a halogenated aromatic hydrocarbon,an ether, an aromatic hydrocarbon and the like. The dispersing medium ispreferably an aliphatic hydrocarbon.

In the case where a dispersing medium is used as the extraction liquid,the organic-inorganic composite particles are blended at a highconcentration in the particle-containing resin molded article and theparticle phase composed of the organic-inorganic composite particles isthree-dimensionally continuous and exposed at the surface of theparticle-containing resin molded article, so that the organic-inorganiccomposite particles can be dispersed (extracted) into the dispersingmedium by continuously withdrawing the organic-inorganic compositeparticles from the exposed surface.

The extraction temperature is, for example, 0 to 150° C. and preferably10 to 100° C. If the extraction temperature is below the above range,the extraction time exceeds the desired limit, which will be describednext, and the producing cost may increase. If, on the other hand, theextraction temperature exceeds the above range, the resin may bedegraded or the producing cost may increase.

The extraction time is, for example, 30 seconds to 5 hours andpreferably 1 minute to 3 hours.

If the extraction time is below the above range, the extractionefficiency will be low. If the extraction time exceeds the above range,the producing cost may increase.

By removing the organic-inorganic composite particles, micropores areformed in the particle-containing resin molded article.

The micropores are formed as openings (gaps) separated by the resinaround the organic-inorganic composite particles.

The shape and dimension (pore size) of micropores are substantially thesame outer shape and dimension as those of the organic-inorganiccomposite particles that have been removed from the resin.

Specifically, in the case where in the particle-containing resin moldedarticle, the organic-inorganic composite particles are blended in theresin at a relatively low concentration and the organic-inorganiccomposite particles are dispersed as primary particles, the microporesare formed as independent pores (closed-cells) dispersed uniformly inthe resin.

As a result, a resin molded article in which micropores are formed, orin other words, a porous molded article can be obtained. In the casewhere the resin molded article is formed as a film, a porous film isobtained.

With the above described method, in the particle-containing resin moldedarticle, the organic-inorganic composite particles are dispersed asprimary particles, and the resin molded article having micropores formedby removing the organic-inorganic composite particles has excellentclarity and excellent mechanical strength.

Accordingly, the resin molded article can be used in, for example,optical applications including optical films such as a low-refractivefilm and an antireflective film, as well as electrical and electronicapplications including electrical and electronic substrates such as alow-dielectric substrate.

Moreover, the resin molded article has independent pores (micropores)formed by removing the organic-inorganic composite particles having anaverage particle size within the above range, and it is thus possible tofurther enhance clarity.

In the case where the resin molded article is used as a low-refractivefilm, for example, the refractive index of the low-refractive film forlight having a wavelength of 633 nm is reduced to, for example, 99% orless of the refractive index of the resin for light having a wavelengthof 633 nm, preferably reduced to 95% or less, more preferably reduced to90% or less. Specifically, the refractive index is, for example, 1 to 3,preferably 1.05 to 2.5 and more preferably 1.1 to 2.

In the case where the resin molded article is used as an antireflectivefilm (low-reflection film), the reflectivity of the antireflective filmfor light having a wavelength of 550 nm is reduced to, for example, 99%or less of the reflectivity of the resin for light having a wavelengthof 550 nm, and preferably reduced to 95% or less. Specifically, thereflectivity of the antireflective film for light having a wavelength of550 nm is, for example, 9% or less, preferably 1 to 8% and morepreferably 1.5 to 7%.

In the case where the resin molded article is used as a low-dielectricsubstrate, the dielectric constant of the low-dielectric substrate isreduced to, for example, 99% or less of the dielectric constant of theresin, preferably reduced to 95% or less, and more preferably reduced to90% or less. Specifically, the dielectric constant of the low-dielectricsubstrate is, for example, 1 to 1000, preferably 1.2 to 100, and morepreferably 1.5 to 100.

On the other hand, with the particle-containing resin molded article, inthe case where the particle-containing resin molded article has a phaseseparated structure formed of a particle phase and a resin phase, morespecifically, a bicontinuous phase separated structure in which theparticle phase is three-dimensionally continuous, the micropores areformed as communicating pores in the resin.

In this case, the resin molded article has communicating pores(micropores) formed by removing the organic-inorganic compositeparticles, and thus has excellent mechanical strength and can be widelyused as a porous film (porous molded article) having paths (passages)formed by communicating pores extending in the thickness direction(front-back surface direction) in various applications such as a sizingfilter, a molecular separation membrane, an adsorptive separation filterand an electrolyte membrane.

In the removal (extraction) of organic-inorganic composite particlesdescribed above, the organic-inorganic composite particles can bepartially left by adjusting the conditions therefor.

In order to partially leave the organic-inorganic composite particles inthe resin molded article, the extraction time is set to, for example,80% or less, preferably 65% or less and more preferably 50% or less ofthe extraction time when the organic-inorganic composite particles arefully extracted. Specifically, the extraction time is, for example, lessthan 60 minutes, preferably 30 minutes or less, and for example, 1second or greater.

In the resin molded article obtained by extraction performed for theextraction time, the proportion of remaining organic-inorganic compositeparticles increases toward one side of the resin molded article,specifically, increases from the surface of the resin molded articletoward the interior (inside). In other words, the proportion of existingmicropores in the resin molded article increases from the interior tothe surface of the resin molded article.

In the resin molded article, the concentration distribution in thethickness direction of the micropores is in a range of, for example, 0to 90 volume %, preferably a range of 0 to 60 volume % and morepreferably a range of 0 to 40 volume %. Specifically, for example, theconcentration of micropores in the surface of the porous film is 90volume % (preferably 65 volume %), the concentration of micropores inthe center portion in the thickness direction of the porous film is 0volume %, and a concentration gradient is formed therebetween.

In the case where the particle-containing resin molded article is formedas a film on the top surface of a substrate, the substrate is laminatedon one side of the film, and the resultant (laminate) can be immersed inan extraction liquid. After that, the laminate is removed from theextraction liquid and dried. Then, the film is peeled off from thesubstrate.

In the porous film obtained by immersing a laminate of a film and asubstrate in an extraction liquid, the proportion of remainingorganic-inorganic composite particles increases toward the back surface(one side in the thickness direction, substrate-side surface). In otherwords, the proportion of existing micropores increases toward thesurface of the porous film (the other side in the thickness direction,the exposed surface on which the substrate is not laminated).

In the porous film in which the organic-inorganic composite particlespartially remain, the concentration distribution in the thicknessdirection of micropores is in a range of, for example, 0 to 90 volume %,preferably a range of 0 to 65 volume % and more preferably a range of 0to 40 volume %. Specifically, for example, the concentration ofmicropores in the surface of the porous film is 90 volume % (preferably65 volume %), the concentration of micropores in the back surface of theporous film is 0 volume %, and a concentration gradient is formed in thethickness direction.

The proportion of remaining organic-inorganic composite particles andthe proportion of existing micropores are measured by SEM or TEM.

The porous film (resin molded article) can be used as a refractive-indexdistribution optical film, a dielectric distribution substrate or thelike because the organic-inorganic composite particles are partiallyleft and the proportion of existing micropores varies in the thicknessdirection of the porous film.

Fifth Embodiment

Embodiment corresponding to the inventions of a titanium complex,titanium oxide particles and a producing method therefor, which areincluded in the fifth group of inventions

The titanium complex of the present invention contains a titanium atomas a central atom and a hydroxycarboxylic acid having a total of 7 ormore carbon atoms as a ligand.

The titanium atom is a transition element having an atomic number of 22and can be, for example, a tetravalent titanium atom.

The hydroxycarboxylic acid is an organic compound that has a total of 7or more carbon atoms and contains a carboxyl group and a hydroxyl group,and it can be, for example, a saturated or unsaturated hydroxycarboxylicacid having a total of 7 or more carbon atoms such as hydroxyalkanoicacid, hydroxyalkenoic acid or hydroxyalkynoic acid.

The total number of carbon atoms of such a hydroxycarboxylic acid ispreferably 8 or greater, for example, 16 or less, and preferably 13 orless.

The number of carboxyl groups contained in the hydroxycarboxylic acidis, for example, 1 to 3 and preferably 1, and the number of hydroxylgroups is, for example, 1 to 3 and preferably 1.

Among the hydroxycarboxylic acids listed above, a hydroxymonocarboxylicacid and a monohydroxycarboxylic acid are preferable, and amonohydroxymonocarboxylic acid is preferable.

Also, among the hydroxycarboxylic acids listed above, a saturatedhydroxyalkanoic acid is preferable. Specific examples include linearhydroxyalkanoic acids having 7 to 16 carbon atoms such ashydroxyheptanoic acid, hydroxyoctanoic acid, hydroxynonanoic acid,hydroxydecanoic acid, hydroxyundecanoic acid, hydroxydodecanoic acid,hydroxytridecanoic acid, hydroxytetradecanoic acid, hydroxypentadecanoicacid and hydroxyhexadecanoic acid; branched hydroxyalkanoic acids having7 to 16 carbon atoms such as hydroxy 3-ethylhexanoic acid, hydroxy4-ethylheptoic acid and hydroxy 3-ethyloctanoic acid; and the like.Among the hydroxyalkanoic acids listed above, linear hydroxyalkanoicacids are preferable.

That is, among the hydroxycarboxylic acids listed above,monohydroxymonoalkanoic acids having a total of 7 to 13 carbon atomssuch as a 2-hydroxyalkanoic acid (α-hydroxyalkanoic acid) and a3-hydroxyalkanoic acid (β-hydroxyalkanoic acid) are particularlypreferable. Specific examples include 2-hydroxyoctanoic acid and3-hydroxydecanoic acid.

Such monohydroxymonoalkanoic acids having a total of 7 to 13 carbonatoms can be used as a ligand constituting a titanium complex.Furthermore, titanium complexes containing such amonohydroxymonoalkanoic acid as a ligand can enhance heat resistance(180° C. or higher) as compared to titanium complexes containing ahydroxycarboxylic acid having a total of 6 or fewer carbon atoms as aligand.

Such a titanium complex is prepared by reacting a hydroxycarboxylic acidhaving a total of 7 or more carbon atoms with a titanium atom.

In order to prepare such a titanium complex, first, a substancecontaining a titanium atom is dissolved in a mixed solution of ahydrogen peroxide solution and an aqueous alkali solution so as to givean unstable aqueous solution of peroxotitanium complex.

The substance containing a titanium atom is not particularly limited,and can be, for example, titanium particles, titanium powders or thelike.

The size (average particle size) of titanium particles or titaniumpowders is not particularly limited.

The titanium particles can be, for example, commercially availabletitanium particles (available from Wako Pure Chemical Industries, Ltd.).

The hydrogen peroxide solution is a solution in which hydrogen peroxide(H₂O₂) is dissolved in water, and has a concentration of, for example,10 to 50 volume % and preferably 20 to 40 volume %.

The aqueous alkali solution can be, for example, aqueous ammonia inwhich ammonia (NH₃) is dissolved in water; an aqueous organic basesolution in which a basic organic compound such as an amine is dissolvedin water; an aqueous inorganic base solution in which a basic inorganiccompound such as sodium hydrogencarbonate is dissolved in water; or thelike.

These aqueous alkali solutions can be used singly or in combination.

Among the aqueous alkali solutions, aqueous ammonia is preferable. Theconcentration of aqueous ammonia is, for example, 1 to 45 mass %,preferably 5 to 40 mass % and more preferably 10 to 35 mass %.

The proportion (hydrogen peroxide solution: aqueous alkali solution) ofthe mixed solution of a hydrogen peroxide solution and an aqueous alkalisolution is, for example, 3:7 to 9:1, preferably 5:5 to 9:1 and morepreferably 6:4 to 9:1.

The pH of the mixed solution is, for example, 6 or greater, preferably 7to 14 and more preferably 9 to 14.

In order to dissolve the substance containing a titanium atom in themixed solution, for example, the substance containing a titanium atom isadded to the mixed solution and, and the resulting mixture is stirredfor a predetermined period of time.

The proportion of the substance containing a titanium atom is, forexample, 0.5 to 5 g and preferably 1 to 3 g per 100 mL of the hydrogenperoxide solution, and is, for example, 0.5 to 5 g and preferably 1 to 2g per 100 mL of the mixed solution.

Stirring conditions are as follows: the temperature is, for example, −15to 80° C., preferably −10 to 50° C. and more preferably −5 to 25° C.;and the time is, for example, 0.1 to 24 hours, preferably 1 to 10 hoursand more preferably 1 to 5 hours.

In the above-described manner, the substance containing a titanium atomis dissolved in the mixed solution, and an aqueous solution ofperoxotitanium complex is prepared.

Specifically, the aqueous solution of peroxotitanium complex contains aperoxotitanium complex formed by reaction of a titanium atom andhydrogen peroxide (H₂O₂).

Next, any one of the hydroxycarboxylic acids having a total of 7 or morecarbon atoms is mixed with the aqueous solution of peroxotitaniumcomplex so as to prepare a titanium complex-containing solution.

In order to mix the hydroxycarboxylic acid with the aqueous solution ofperoxotitanium complex, for example, the hydroxycarboxylic acid isdissolved in a solvent so as to prepare a hydroxycarboxylic acidsolution, and the hydroxycarboxylic acid solution and the aqueoussolution of peroxotitanium complex are mixed and stirred. Afterstirring, if necessary, the mixture is allowed to stand still for, forexample, 10 to 40 hours.

There is no particular limitation on the solvent as long as thehydroxycarboxylic acid can be dissolved. Examples include water,alcohols such as methanol and ethanol, ketones such as acetone andmethyl ethyl ketone, and the like.

These solvents can be used singly or in combination.

Among the solvents, alcohols are preferable.

The concentration of the hydroxycarboxylic acid solution is, forexample, 0.1 to 80 mass %, preferably 1 to 50 mass % and more preferably5 to 30 mass %.

The proportion of the hydroxycarboxylic acid solution is, for example,10 to 100 mL, preferably 20 to 80 mL and more preferably 30 to 60 mL per100 mL of the aqueous solution of peroxotitanium complex.

The proportion of hydroxycarboxylic acid is, for example, 1 to 6 mol,preferably 1 to 5 mol, and more preferably 1 to 4 mol per mol of thesubstance containing a titanium atom.

If the proportion of hydroxycarboxylic acid is less than 1 mol per molof the substance containing a titanium atom, a titanium complex cannotbe formed due to the shortage of ligand, and so a by-product containinga ligand (hydroxycarboxylic acid) and titanium atoms that do not formthe complex may be left, and the desired titanium oxide particles maynot be obtained from the titanium complex containing the by-product. If,on the other hand, the proportion of hydroxycarboxylic acid exceeds 6mol per mol of the substance containing a titanium atom, the amount ofhydroxycarboxylic acid will be excessive and wasted, and thus it may beinappropriate in terms of cost. Also, in this case, it is necessary toremove excessive hydroxycarboxylic acid left after the titanium oxideparticle producing step, which makes the producing process complex. If,on the other hand, the proportion of hydroxycarboxylic acid is withinthe above range, the efficiency of titanium oxide particle producing canbe enhanced.

Stirring conditions are as follows: the temperature is, for example, 0to 80° C., preferably 5 to 70° C. and more preferably 10 to 60° C.; andthe time is, for example, 0.1 to 24 hours, preferably 0.5 to 10 hoursand more preferably 1 to 5 hours. After stirring, if necessary, themixture is allowed to stand still for, for example, 10 to 40 hours.

By mixing and stirring a hydroxycarboxylic acid and an aqueous solutionof peroxotitanium complex as described above, the hydroxycarboxylic acidis reacted with the peroxotitanium complex contained in the aqueoussolution of peroxotitanium complex, as a result of which a titaniumcomplex is formed. Accordingly, a titanium complex-containing solutionthat contains a titanium complex is prepared.

Next, the obtained titanium complex-containing solution is dried toprepare a titanium complex.

There is no particular limitation on the drying method, and knownmethods such as vacuum drying, spray drying and freeze drying can beused. For example, the solvent is dried by increasing the temperaturewith a drier or the like to prepare a titanium complex.

There is no particular limitation on the drying conditions as long asthe solvent can be removed. The temperatures is, for example, 50 to 100°C. and preferably 60 to 90° C., and the time is 0.1 to 48 hours,preferably 0.5 to 24 hours and more preferably 1 to 10 hours.

In the above-described manner, a titanium complex is prepared.

The coordination number of the titanium complex is, for example, 1 to 6preferably 2 to 4 per titanium atom. The coordination number can beanalyzed with, for example, a mass spectrometer such as a matrixassisted laser desorption ionization (MALDI)—time-of-flight (TOF) massspectrometer (MS), or the like

The yield of the titanium complex is, for example, 60 to 100 mol % andpreferably 80 to 100 mol % relative to the substance containing atitanium atom used.

There is no limitation on the applications of the titanium complexprepared in this manner. For example, the titanium complex is subjectedto thermal decomposition to produce titanium oxide particles.Specifically, for example, the titanium complex is subjected to ahigh-temperature and high-pressure treatment (hydrothermal synthesis) inwater to produce titanium oxide particles.

To produce titanium oxide particles, first, the titanium complex andwater are introduced into a reactor.

The proportion of the titanium complex is, for example, 5 to 40 parts bymass, preferably 10 to 30 parts by mass per 100 parts by mass of water.

The reactor can be a known high-pressure reactor (autoclave) orcontinuous high-pressure reactor.

An example of such a high-pressure reactor (autoclave) is a commerciallyavailable high-pressure reactor (available from AKICO Corporation).Another example of a continuous high-pressure reactor is a commerciallyavailable continuous high-pressure reactor (available from ITEC Co.Ltd.).

Then, the reactor is brought to high-temperature and high-pressureconditions, whereby titanium oxide particles are produced (hydrothermalsynthesis).

Reaction conditions for the hydrothermal synthesis are the same as thosefor the hydrothermal synthesis (first hydrothermal synthesis)illustrated in the third embodiment.

The reaction product obtained by the above hydrothermal synthesisincludes a precipitate that mostly precipitates in water and a depositthat adheres to the inner wall of the airtight container.

There is no particular limitation on the method for separating andrecovering a precipitate, and it is possible to use known methods thatuse a separating funnel, a filter, centrifugal separation and the like.The precipitate can be separated and recovered by using any of themethods. The precipitate is obtained by, for example, sedimentationseparation in which the reaction product is settled by gravity or acentrifugal field. Preferably, the precipitate is obtained as aprecipitate of the reaction product by centrifugal sedimentation(centrifugal separation) in which the reaction product is settled by acentrifugal field.

The deposit is recovered by, for example, a scraper (spatula) or thelike.

The reaction product can also be recovered (separated) by adding asolvent to wash away unreacted hydroxycarboxylic acid (or in otherwords, dissolving the hydroxycarboxylic acid in the solvent) andthereafter removing the solvent.

The solvent can be, for example, any of the solvents listed above.

These solvents can be used singly or in combination.

Among the solvents, an alcohol is preferable.

The washed reaction product is separated from the solvent (supernatantliquid) by, for example, filtration, decantation or the like, andrecovered. After that, the reaction product is dried by, for example,application of heat, an air stream or the like if necessary.

In the manner described above, titanium oxide particles are preparedfrom the titanium complex.

The titanium oxide particles have a crystal structure of, for example,anatase (tetragonal crystal), rutile (tetragonal crystal) or brookite(orthorhombic crystal). The crystal structure can be determined byelectron diffraction such as XRD (X-ray diffraction) or TEM(transmission electron microscope).

There is no particular limitation on the crystal structure, and thecrystal structure can be selected as appropriate by changing the type ofligand and the conditions for synthesizing titanium oxide. For example,the crystal structure is preferably rutile when used as an opticalmaterial having a high refractive index, and is preferably anatase whenused as a catalyst material that exerts photocatalytic function.

As described above, the titanium oxide particles of the presentinvention are prepared by treating a titanium complex containing ahydroxyl carboxylic acid having a total of 7 or more carbon atoms as aligand in hot high pressure water.

At this time, because the ligand of the titanium complex is a hydroxylcarboxylic acid having a total of 7 or more carbon atoms, decompositionof the ligand is suppressed even in hot high pressure water, as a resultof which coloring of the resulting titanium oxide particles can bereduced.

Therefore, according to the present invention, reduction of coloring ofthe titanium oxide particles can be achieved while achieving reductionof the environmental load.

The applications of the titanium oxide particles of the presentinvention can be, for example, various industrial products, and opticalapplications and the like are preferable because coloring is reduced.

EXAMPLES

Hereinafter, examples and the like that correspond to the first to fifthgroups of inventions that are included in the present invention andrelated to each other will be described in sequence.

Examples, Comparative Examples, Preparation Examples and ProducingExamples Corresponding to the First Group of Inventions

The first group of inventions will be described in further detail byshowing Examples, Comparative Examples, Preparation Examples andProducing Examples corresponding to the first group of inventions, butthe first group of inventions is not limited thereto.

The following is a description of evaluation methods for obtainedparticles, particle dispersions and resin molded articles (includingoptical films).

(1) X-Ray Diffractometry (XRD)

Particles were loaded into a glass holder and subjected to X-raydiffractometry under the following conditions. After that, from theobtained peaks, the components of the primary particles were assigned bydatabase search.

X-ray diffractometer: D8 DISCOVER with GADDS, available from Bruker AXS

(Optical system on incident side)

X-ray source: CuKα (λ=1.542 Å), 45 kV, 360 mA

Spectroscope (monochromator): multilayer mirror

Collimator diameter: 300 μm

(Optical system on light-receiving side)

Counter: two-dimensional PSPC (Hi-STAR)

Distance between particles and counter: 15 cm

2θ=20, 50, 80 degrees, ω=10, 25, 40 degrees, Phi=0 degrees, Psi=0degrees

Measurement time: 10 minutes

Assignment (semiquantitation software): FPM EVA, available from BrukerAXS

(2) Fourier Transform Infrared Spectrophotometry (FT-IR)

Fourier transform infrared spectrophotometry was carried out accordingto the KBr method using the following apparatus.

Fourier transform infrared spectrophotometer: FT/IRplus, available fromJASCO Corporation

(3) Observation with Field Emission-Scanning Electron Microscope(FE-SEM)

(a) Observation of Particle Surface and Measurement of Lengthwise Length(Maximum Length) LL and Sideways Length (Minimum Length) SL

A sample was produced by dispersing particles on a sample stage andcoating the particles with osmium. Next, the prepared sample wasphotographed with the following field emission-scanning electronmicroscope (FE-SEM).

In the obtained FE-SEM micrograph, the lengthwise length (maximumlength) LL and sideways length (minimum length) SL of each particle weremeasured, and then the lengthwise length LL and sideways length SL ofthe entire particles were calculated from the arithmetic mean of themeasured values.

FE-SEM: JSM-7500F, available from JEOL Ltd.

Acceleration voltage: 2 kV

(b) Observation of Cross-Section of Resin Molded Articles (IncludingOptical Films)

A sample was produced by machining a resin molded article (including anoptical film) with a cross section polisher (SM-08010, available fromJEOL Ltd.). After that, the prepared sample was coated with osmium, anda cross section of the sample was observed with the following fieldemission-scanning electron microscope (FE-SEM).

FE-SEM: JSM-7001F, available from JEOL Ltd.

Acceleration voltage: 5 kV

(4) Observation with Transmission Electron Microscope (TEM)

Particles were dispersed on a Cu mesh having a microgrid support film,and the particles were observed with a transmission electron microscope(TEM).

TEM: HF-2000, available from Hitachi High-Tech Manufacturing & ServiceCorporation

Acceleration voltage: 200 kV

(5) Particle Size Distribution Measurement

A particle dispersion was placed in a quartz cell, and particle sizedistribution was measured with the following particle size distributionmeasuring apparatus.

Particle size distribution measuring apparatus: Zetasizer Nano-Zs,available from Marvern Instruments

Example 1-1

Strontium hydroxide octahydrate (available from Wako Pure ChemicalIndustries, Ltd.) in an amount of 0.5 g, formic acid (available fromWako Pure Chemical Industries, Ltd.) in an amount of 0.0896 mL, decanoicacid (available from Wako Pure Chemical Industries, Ltd.) in an amountof 0.2332 mL and pure water in an amount of 2.032 mL were introducedinto a 5 mL high-pressure reactor (available from AKICO Corporation).

Next, the high-pressure reactor was closed with a cover, heated to 400°C. in a shaking furnace (available from AKICO Corporation) so as topressurize the inside of the high-pressure reactor to 40 MPa, and thenshaken for 10 minutes for hydrothermal synthesis.

After that, the high-pressure reactor was plunged into cold water forquenching.

Next, because decanoic acid dissolves in ethanol, ethanol (availablefrom Wako Pure Chemical Industries, Ltd.) was added, and the mixture wasstirred and subjected to centrifugal separation performed in acentrifuge (trade name: MX-301, available from Tomy Seiko Co., Ltd.) at12000 G for 10 minutes to separate a precipitate (reaction product) froma supernatant (washing step). This washing operation was repeated 5times so as to remove the remaining decanoic acid, and thereby particleswere obtained.

After that, the obtained particles were evaluated by (1) XRD, (2) FT-IRand (3) FE-SEM.

The formulation of respective components and the evaluation results inExample 1-1 are presented in Table 1, and an image-processed FE-SEMmicrograph in Example 1-1 is shown in FIG. 1.

As a result, (1) XDR confirmed that the inorganic compound forming theinorganic particles was SrCO₃.

(2) FT-IR confirmed C—H stretching vibrations from 2800 to 3000 cm⁻¹ andthe presence of C—H bonds on the surface of the inorganic particles.

(3) FE-SEM confirmed that the primary particles had an acicular shapewith a sideways length SL of approximately 0.1 to 0.5 μm and alengthwise length LL of approximately 0.8 to 6 μm with reference toFIG. 1. It was also confirmed that the aspect ratio of the primaryparticles was 8 to 60 as a result of calculation from FIG. 1.

Examples 1-2 to 1-16

Particles were obtained in the same manner as in Example 1-1 accordingto the formulation and treatment conditions presented in Table 1, andthen subjected to evaluation in the same manner as in Example 1-1. Theresults are presented in Table 1.

Comparative Example 1-1

Strontium hydroxide octahydrate (available from Wako Pure ChemicalIndustries, Ltd.) in an amount of 0.5 g and pure water in an amount of2.355 mL were introduced into a 5 mL high-pressure reactor (availablefrom AKICO Corporation).

Next, the high-pressure reactor was closed with a cover, heated to 400°C. in a shaking furnace (available from AKICO Corporation) so as topressurize the inside of the high-pressure reactor to 40 MPa, and thenshaken for 10 minutes for hydrothermal synthesis.

After that, the high-pressure reactor was plunged into cold water forquenching.

Next, pure water was added, and the mixture was stirred and subjected tocentrifugal separation performed in a centrifuge (trade name: MX-301,available from Tomy Seiko Co., Ltd.) at 12000 G for 10 minutes, andthereby a precipitate was separated from a supernatant and dried to giveparticles.

After that, the obtained particles were evaluated by (1) XRD describedabove.

The formulation of respective components and the evaluation results inComparative Example 1-1 are presented in Table 1.

(1) XDR confirmed that the inorganic compound forming the inorganicparticles was SrCO₃.

Comparative Example 1-2

Strontium hydroxide octahydrate (available from Wako Pure ChemicalIndustries, Ltd.) in an amount of 0.5 g, formic acid (available fromWako Pure Chemical Industries, Ltd.) in an amount of 0.0896 mL and purewater in an amount of 2.265 mL were introduced into a 5 mL high-pressurereactor (available from AKICO Corporation).

Next, the high-pressure reactor was closed with a cover, heated to 400°C. in a shaking furnace (available from AKICO Corporation) so as topressurize the inside of the high-pressure reactor to 40 MPa, and thenshaken for 10 minutes for hydrothermal synthesis.

After that, the high-pressure reactor was plunged into cold water forquenching.

Next, ethanol (available from Wako Pure Chemical Industries, Ltd.) wasadded, and the mixture was stirred and subjected to centrifugalseparation performed in a centrifuge (trade name: MX-301, available fromTomy Seiko Co., Ltd.) at 12000 G for 10 minutes to separate aprecipitate (reaction product) from a supernatant (washing step). Thiswashing operation was repeated 5 times, and thereby particles wereobtained.

After that, the obtained particles were evaluated by (1) XRD, (2) FT-IRand (3) FE-SEM.

The formulation of respective components and the evaluation results inComparative Example 1-2 are presented in Table 1, and an image-processedFE-SEM micrograph in Comparative Example 1-2 is shown in FIG. 2.

(1) XDR confirmed that the inorganic compound forming the inorganicparticles was SrCO₃.

(2) FT-IR confirmed no C—H stretching vibrations from 2800 to 3000 cm⁻¹.

(3) FE-SEM confirmed that the primary particles had an acicular shapewith a sideways length SL of approximately 200 nm to 1 μm and alengthwise length LL of approximately 0.8 to 7.5 μm with reference toFIG. 2. It was also confirmed that the aspect ratio of the primaryparticles was 4 to 37 as a result of calculation from FIG. 2.

TABLE 1 Formulations pH adjusting Composition Inorganic Carbonic acidagent Pure of compound Organic compound source Type (pH water Ex.inorganic Amount Hydrophobic/ Amount Amount of reaction Amount AmountComp. Ex. particles *1 Type (g) hydrophilic Type (mL) Type (mL) system)(mL) (mL) Ex. 1-1 SrCO₃ Sr(OH)₂•8H₂O 0.5 Hydrophobic Decanoic acid0.2332 Formic acid 0.0896 — 2.032 Ex. 1-2 SrCO₃ Sr(OH)₂•8H₂O 0.5Hydrophobic Decanoic acid 0.9326 Formic acid 0.0299 1.333 Ex. 1-3 SrCO₃Sr(OH)₂•8H₂O 0.1 Hydrophobic Decanoic acid 0.259 Formic acid 0.08962.328 Ex. 1-4 SrCO₃ Sr(OH)₂•8H₂O 0.5 Hydrophobic Decanoic acid 0.04664Formic acid 0.0896 2.219 Ex. 1-5 SrCO₃ Sr(OH)₂•8H₂O 0.5 HydrophobicDecanoic acid 0.2332 Formic acid 0.1792 1.942 Ex. 1-6 SrCO₃ Sr(OH)₂•8H₂O0.17 Hydrophobic Decanoic acid 0.088 Formic acid 0.0338 0.767 Ex. 1-7SrCO₃ Sr(OH)₂•8H₂O 0.342 Hydrophobic Decanoic acid 0.1768 Formic acid0.0679 1.542 Ex. 1-8 SrCO₃ Sr(OH)₂•8H₂O 0.5 Hydrophobic Decanoic acid0.2332 Formic acid 0.0896 2.032 Ex. 1-9 SrCO₃ Sr(OH)₂•8H₂O 0.5Hydrophobic Decanoic acid 0.2332 Formic acid 0.08955 2.032 Ex. 1-10SrCO₃ Sr(OH)₂•8H₂O 1 Hydrophobic Decanoic acid 0.2332 Formic acid 0.15921.962 Ex. 1-11 SrCO₃ Sr(OH)₂•8H₂O 0.5 Hydrophobic Diethyl- 0.3278 Formicacid 0.0896 1.937 dodecyl- phosphonate Ex. 1-12 SrCO₃ Sr(OH)₂•8H₂O 0.5Hydrophobic Hexanoic acid 0.1475 Formic acid 0.0896 2.118 Ex. 1-13 SrCO₃Sr(OH)₂•8H₂O 0.5 Hydrophobic Laric acid 0.2359 Formic acid 0.0896 2.029Ex. 1-14 SrCO₃ Sr(OH)₂•8H₂O 0.5 Hydrophobic 6- 0.2198 Formic acid 0.08962.045 Phenylhexanoic acid Ex. 1-15 SrCO₃ Sr(OH)₂•8H₂O 0.5 HydrophobicDecylamine 0.1948 Formic acid 0.0896 2.07 Ex. 1-16 SrCO₃ Sr(OH)₂•8H₂O0.5 Hydrophobic Decanoic acid 0.2332 Formic acid 0.0896 1.885 Hexanoicacid 0.1475 Comp. SrCO₃ Sr(OH)₂•8H₂O 0.5 — — 2.355 Ex. 1-1 Comp. SrCO₃Sr(OH)₂•8H₂O 0.5 — Formic acid 0.0896 2.265 Ex. 1-2 Evaluation Primaryparticles Particle size Treatment SL: Sideways Dispersibility conditionslength Solvent of Ex. Temp. Pressure Time LL: Lengthwise Aspect particledispersion *2 Resin molded Comp. Ex. ° C. MPa Min. length ratioChloroform Cyclohexane article *3 Optical film *4 Ex. 1-1 400 40 10 SL:0.1-0.5 μm 8-60 Dispersed as — Dispersed as Dispersed as LL: 0.8-6 μmprimary particles primary particles primary particles Ex. 1-2 400 40 10SL: 3-4 μm 15-5  Dispersed as Dispersed as Dispersed as LL: 4-1.25 μmprimary particles primary particles primary particles Ex. 1-3 400 40 10SL: 1-2.5 μm 3-6  Dispersed as Dispersed as Dispersed as LL: 3-6 μmprimary particles primary particles primary particles Ex. 1-4 400 40 10SL: 0.2-0.6 μm 3-35 Dispersed as Dispersed as Dispersed as LL: 0.6-7 μmprimary particles primary particles primary particles Ex. 1-5 400 40 10SL: 0.2-1.8 μm 3-25 Dispersed as Dispersed as Dispersed as LL: 0.6-5 μmprimary particles primary particles primary particles Ex. 1-6 500 40 10SL: 0.2-0.75 μm 3-27 Dispersed as Dispersed as Dispersed as LL: 0.6-5.5μm primary particles primary particles primary particles Ex. 1-7 400 3010 SL: 0.4-0.6 μm 25-15  Dispersed as Dispersed as Dispersed as LL: 1-6μm primary particles primary particles primary particles Ex. 1-8 350 173 SL: 0.1-0.5 μm 5-30 Dispersed as Dispersed as Dispersed as LL: 0.5-3μm primary particles primary particles primary particles Ex. 1-9 400 40120 SL: 0.1-0.4 μm 2-50 Dispersed as Dispersed as Dispersed as LL: 0.2-5μm primary particles primary particles primary particles Ex. 1-10 400 40120 SL: 0.4-0.8 μm  1-100 Dispersed as Dispersed as Dispersed as LL:0.3-4.0 μm primary particles primary particles primary particles Ex.1-11 400 40 10 SL: 0.5-0.8 μm 10-36  Dispersed as Dispersed as Dispersedas LL: 5-1.8 μm primary particles primary particles primary particlesEx. 1-12 400 40 10 SL: 0.1-0.5 μm 8-75 Dispersed as Dispersed asDispersed as LL: 0.8-7.5 μm primary particles primary particles primaryparticles Ex. 1-13 400 40 10 SL: 0.1-0.6 μm 5-20 Dispersed as Dispersedas Dispersed as LL: 0.5-2 μm primary particles primary particles primaryparticles Ex. 1-14 400 40 10 SL: 0.1-0.55 μm 6-55 Dispersed as Dispersedas Dispersed as LL: 0.6-5.5 μm primary particles primary particlesprimary particles Ex. 1-15 400 40 10 SL: 0.2-1 μm 5-20 Dispersed asDispersed as Dispersed as LL: 1-4 μm primary particles primary particlesprimary particles Ex. 1-16 400 40 10 SL: 0.5-0.8 μm 14-30  Dispersed asDispersed as Dispersed as LL: 7-1.5 μm primary particles primaryparticles primary particles Comp. 400 40 10 — — — — — Ex. 1-1 Comp. 40040 10 SL: 0.2-1 μm 4-37 Coagulated Coagulated Coagulated Ex. 1-2 LL:0.8-7.5 μm *1: Negative birefringence *2: Preparation Example 1-1 *3:Production Example 1-1, Size: diameter of 10 mm, thickness of 5 mm *4:Production Example 1-2, Size: thickness of 20 μm

Example 1-17

Strontium hydroxide octahydrate (available from Wako Pure ChemicalIndustries, Ltd.) in an amount of 0.5 g, formic acid (available fromWako Pure Chemical Industries, Ltd.) in an amount of 0.0896 mL, oleicacid (available from Wako Pure Chemical Industries, Ltd.) in an amountof 0.3737 mL and aqueous ammonia in an amount of 1.892 mL wereintroduced into a 5 mL high-pressure reactor (available from AKICOCorporation). The amount of aqueous ammonia was adjusted such that theresulting reaction system had a pH of 10.

Next, the high-pressure reactor was closed with a cover, heated to 400°C. in a shaking furnace (available from AKICO Corporation) so as topressurize the inside of the high-pressure reactor to 40 MPa, and thenshaken for 10 minutes for hydrothermal synthesis.

After that, the high-pressure reactor was plunged into cold water forquenching.

Next, because oleic acid dissolves in ethanol, ethanol (available fromWako Pure Chemical Industries, Ltd.) was added, and the mixture wasstirred and subjected to centrifugal separation performed in acentrifuge (trade name: MX-301, available from Tomy Seiko Co., Ltd.) at12000 G for 10 minutes to separate a precipitate (reaction product) froma supernatant (washing step). This washing operation was repeated 5times so as to remove the remaining oleic acid, and thereby particleswere obtained.

After that, the obtained particles were evaluated by (1) XRD, (2) FT-IRand (4) TEM described above.

The formulation of respective components and the evaluation results inExample 1-17 are presented in Table 2, and an image-processed TEMmicrograph is shown in FIG. 3.

(1) XDR confirmed that the inorganic compound forming the inorganicparticles was SrCO₃.

(2) FT-IR confirmed C—H stretching vibrations from 2800 to 3000 cm⁻¹ andthe presence of C—H bonds on the surface of the inorganic particles.

(4) TEM confirmed that the primary particles had an acicular shape witha sideways length SL of approximately 20 to 100 nm and a lengthwiselength LL of approximately 60 to 280 nm with reference to FIG. 3. It wasalso confirmed that the aspect ratio of the primary particles was 3 to14 as a result of calculation from FIG. 3.

Examples 1-18 to 1-28

Particles were obtained in the same manner as in Example 1-17 accordingto the formulation and treatment conditions presented in Table 2, andthen subjected to evaluation in the same manner as in Example 1-17. Theresults are presented in Table 2.

TABLE 2 Formulations Inorganic Carbonic acid pH adjusting agentComposition of compound Organic compound source Type (pH of inorganicAmount Hydrophobic/ Amount Amount reaction Amount Ex. particles *1 Type(g) hydrophilic Type (mL) Type (mL) system) (mL) Ex. 1-17 SrCO₃Sr(OH)₂•8H₂O 0.5 Hydrophobic Oleic acid 0.3737 Formic acid 0.0896Aqueous 1.89 ammonia (pH = 10) Ex. 1-18 SrCO₃ Sr(OH)₂•8H₂O 0.5Hydrophobic Decanoic acid 0.2332 Formic acid 0.0896 Aqueous 2.03 ammonia(pH = 10) Ex. 1-19 SrCO₃ Sr(OH)₂•8H₂O 0.5 Hydrophobic Decanoic acid0.2332 Formic acid 0.0896 Aqueous 2.03 ammonia (pH = 11) Ex. 1-20 SrCO₃Sr(OH)₂•8H₂O 0.3 Hydrophobic Decanoic acid 0.5181 Formic acid 0.0995Aqueous 2 ammonia (pH = 12) Ex. 1-21 SrCO₃ Sr(OH)₂•8H₂O 0.5 HydrophobicDecanoic acid 0.5181 Formic acid 0.0995 Aqueous 2 ammonia (pH = 12) Ex.1-22 SrCO₃ Sr(OH)₂•8H₂O 0.5 Hydrophobic Decanoic acid 0.2332 Formic acid0.0896 Aqueous 2.03 ammonia (pH = 8) Ex. 1-23 SrCO₃ Sr(OH)₂•8H₂O 0.5Hydrophobic Decanoic acid 0.2332 Urea 0.1414 Aqueous 1.98 ammonia (pH =10) Ex. 1-24 SrCO₃ Sr(OH)₂•8H₂O 0.5 Hydrophobic Decanoic acid 0.2332Formic acid 0.0896 Aqueous 2.03 ammonia (pH = 12) Ex. 1-25 SrCO₃Sr(OH)₂•8H₂O 0.5 Hydrophobic Decanoic acid 0.2332 Formic acid 0.0896Aqueous 2.03 ammonia (pH = 10) Ex. 1-26 SrCO₃ Sr(OH)₂•8H₂O 0.5Hydrophobic 6-Phenylhexanoic 0.2198 Formic acid 0.0896 Aqueous 2.05 acidammonia (pH = 10) Ex. 1-27 SrCO₃ Sr(OH)₂•8H₂O 0.5 Hydrophilic Decylamine0.1948 Formic acid 0.0896 Aqueous 2.07 ammonia (pH = 10) Ex. 1-28 SrCO₃Sr(OH)₂•8H₂O 0.3 Hydrophobic Decanoic acid 0.2591 Formic acid 0.0995Aqueous 2.09 Hexanoic acid 0.164 ammonia (pH = 12) Evaluation Primaryparticles Particle size SL: Sideways Dispersibility Treatment conditionslength Solvent of Temp. Pressure Time LL: Lengthwise Aspect particledispersion *2 Resin molded Ex. ° C. MPa Min. length ratio ChloroformCyclohexane article *3 Optical film *4 Ex. 1-17 400 40 10 SL: 0.02-0.1μm 3-14 Dispersed as — Dispersed as Dispersed as LL: 0.06-0.28 μmprimary particles primary particles primary particles Ex. 1-18 400 40 10SL: 0.05-0.25 μm 10-40  Dispersed as Dispersed as Dispersed as LL: 0.5-2μm primary particles primary particles primary particles Ex. 1-19 400 4010 SL: 0.1-0.5 μm 4-50 Dispersed as Dispersed as Dispersed as LL: 0.4-5μm primary particles primary particles primary particles Ex. 1-20 400 4010 SL: 0.01-0.04 μm 5-20 Dispersed as Dispersed as Dispersed as LL:0.05-0.2 μm primary particles primary particles primary particles Ex.1-21 400 40 10 SL: 0.01-0.02 μm 5-20 Dispersed as Dispersed as Dispersedas LL: 0.05-0.2 μm primary particles primary particles primary particlesEx. 1-22 400 40 10 SL: 0.04-0.25 μm 13-50  Dispersed as Dispersed asDispersed as LL: 0.05-2 μm primary particles primary particles primaryparticles Ex. 1-23 400 40 10 SL: 0.1-0.2 μm 10-60  Dispersed asDispersed as Dispersed as LL: 1-6 μm primary particles primary particlesprimary particles Ex. 1-24 400 40 10 SL: 0.17-0.3 μm 8-23 Dispersed asDispersed as Dispersed as LL: 1.3-4 μm primary particles primaryparticles primary particles Ex. 1-25 400 40 3 SL: 0.075-0.2 μm 4-24Dispersed as Dispersed as Dispersed as LL: 0.3-1.8 μm primary particlesprimary particles primary particles Ex. 1-26 400 40 10 SL: 0.07-0.18 μm23-38  Dispersed as Dispersed as Dispersed as LL: 0.16-2.7 μm primaryparticles primary particles primary particles Ex. 1-27 400 40 10 SL:0.125-0.35 μm 4-42 Dispersed as Dispersed as Dispersed as LL: 0.43-5.3μm primary particles primary particles primary particles Ex. 1-28 400 4010 SL: 0.01-0.04 μm 2-20 Dispersed as Dispersed as Dispersed as LL:0.02-0.2 μm primary particles primary particles primary particles *1:Negative birefringence *2: Preparation Example 1-1 *3: ProductionExample 1-1, Size: diameter of 10 mm, thickness of 5 mm *4: ProductionExample 1-2, Size: thickness of 20 μm

Example 1-29

Strontium carbonate (available from Honjo Chemical Corporation) in anamount of 0.5 g, decanoic acid (available from Wako Pure ChemicalIndustries, Ltd.) in an amount of 0.2332 mL and pure water in an amountof 2.122 mL were introduced into a 5 mL high-pressure reactor (availablefrom AKICO Corporation).

Next, the high-pressure reactor was closed with a cover, heated to 400°C. in a shaking furnace (available from AKICO Corporation) so as topressurize the inside of the high-pressure reactor to 40 MPa, and thenshaken for 10 minutes for hydrothermal synthesis.

After that, the high-pressure reactor was plunged into cold water forquenching.

Next, because decanoic acid dissolves in ethanol, ethanol (availablefrom Wako Pure Chemical Industries, Ltd.) was added, and the mixture wasstirred and subjected to centrifugal separation performed in acentrifuge (trade name: MX-301, available from Tomy Seiko Co., Ltd.) at12000 G for 10 minutes to separate a precipitate (reaction product) froma supernatant (washing step). This washing operation was repeated 5times so as to remove the remaining decanoic acid, and thereby particleswere obtained.

After that, the obtained particles were evaluated by (1) XRD, (2) FT-IRand (3) FE-SEM described above.

The formulation of respective components and the evaluation results inExample 1-29 are presented in Table 3, and an image-processed FE-SEMmicrograph in Example 1-29 is shown in FIG. 4.

As a result, (1) XDR confirmed that the inorganic compound forming theinorganic particles was SrCO₃.

(2) FT-IR confirmed C—H stretching vibrations from 2800 to 3000 cm⁻¹ andthe presence of C—H bonds on the surface of the inorganic particles.

(3) FE-SEM confirmed that the primary particles had an acicular shapewith a sideways length SL of approximately 140 to 210 nm and alengthwise length LL of approximately 400 nm to 1 μm with reference tothe image-processed micrograph shown in FIG. 4. It was also confirmedthat the aspect ratio of the primary particles was 3 to 5 as a result ofcalculation from the image-processed micrograph shown in FIG. 4.

Examples 1-30 to 1-46

Particles were obtained in the same manner as in Example 1-29 accordingto the formulation and treatment conditions presented in Table 3, andthen subjected to evaluation in the same manner as in Example 1-29. Theresults are presented in Table 3.

Comparative Example 1-3

Strontium carbonate (available from Honjo Chemical Corporation) in anamount of 0.5 g and pure water in an amount of 2.355 mL were introducedinto a 5 mL high-pressure reactor (available from AKICO Corporation).

Next, the high-pressure reactor was closed with a cover, heated to 400°C. in a shaking furnace (available from AKICO Corporation) so as topressurize the inside of the high-pressure reactor to 40 MPa, and thenshaken for 10 minutes for hydrothermal synthesis.

After that, the high-pressure reactor was plunged into cold water forquenching.

Next, a reaction product was recovered using ethanol (available fromWako Pure Chemical Industries, Ltd.) and subjected to centrifugalseparation performed in a centrifuge (trade name: MX-301, available fromTomy Seiko Co., Ltd.) at 12000 G for 10 minutes, and thereafter aprecipitate was separated from a supernatant and dried to giveparticles.

After that, the obtained particles were evaluated by (1) XRD, (2) FT-IRand (3) FE-SEM described above.

The formulation of respective components and the evaluation results inComparative Example 1-3 are presented in Table 3, and an image-processedFE-SEM micrograph in Comparative Example 1-3 is shown in FIG. 5.

(1) XDR confirmed that the inorganic compound forming the inorganicparticles was SrCO₃.

(2) FT-IR confirmed no C—H stretching vibrations from 2800 to 3000 cm⁻¹.

(3) FE-SEM confirmed that the primary particles had an acicular shapewith a sideways length SL of approximately 140 to 210 nm and alengthwise length LL of approximately 400 nm to 1 μm with reference toFIG. 5. It was also confirmed that the aspect ratio of the primaryparticles was 3 to 5 as a result of calculation from FIG. 5.

TABLE 3 Formulations Carbonic pH adjusting Composition Inorganic acidagent of compound Organic compound source Type (pH Pure water Ex.inorganic Amount Hydrophobic/ Amount Amount of reaction Amount AmountComp. Ex. particles *1 Type (g) hydrophilic Type (mL) Type (mL) system)(mL) (mL) Ex. 1-29 SrCO₃ SrCO₃ 0.5 Hydrophobic Decanoic acid 0.2332 — —2.122 Ex. 1-30 SrCO₃ SrCO₃ 0.5 Hydrophobic Decanoic acid 0.3406 3.099Ex. 1-31 SrCO₃ SrCO₃ 0.5 Hydrophobic Decanoic acid 0.3716 3.382 Ex. 1-32SrCO₃ SrCO₃ 0.5 Hydrophobic Decylamine 0.2845 3.155 Ex. 1-33 SrCO₃ SrCO₃0.5 Hydrophobic 6-Phenylhexanoic acid 0.3503 3.403 Ex. 1-34 SrCO₃ SrCO₃0.5 Hydrophobic Decylphosphonic acid 0.3823 3.057 Ex. 1-35 SrCO₃ SrCO₃0.5 Hydrophobic Decylphosphonic acid 0.2617 3.057 Ex. 1-36 SrCO₃ SrCO₃0.5 Hydrophobic Cyclohexanepentanoic acid 0.2511 2.365 Ex. 1-37 SrCO₃SrCO₃ 0.5 Hydrophobic Norbornene decanoic acid 0.5 3.253 Ex. 1-38 SrCO₃SrCO₃ 0.5 Hydrophobic Trioctylphosphin oxide 0.7255 3.028 Ex. 1-39 SrCO₃SrCO₃ 0.5 Hydrophobic 10-Undecenoic acid 0.3458 3.407 Ex. 1-40 SrCO₃SrCO₃ 0.5 Hydrophobic Decanoic acid 0.1858 3.45 SrCO₃ SrCO₃ Hexanoicacid 0.1176 Ex. 1-41 SrCO₃ SrCO₃ 0.5 Hydrophobic Norbornene decanoicacid 0.25 3.386 SrCO₃ SrCO₃ Hexanoic acid 0.1176 Ex. 1-42 SrCO₃ SrCO₃0.5 Hydrophobic Cyclopentane decanoic acid 0.2255 3.41 SrCO₃ SrCO₃Hexanoic acid 0.1176 Ex. 1-43 SrCO₃ SrCO₃ 0.5 Hydrophilic Ethyl6-hydroxyhexanoate 0.2332 2.122 Ex. 1-44 SrCO₃ SrCO₃ 0.5 Hydrophilic4-Oxovaleric acid 0.2332 2.122 Ex. 1-45 SrCO₃ SrCO₃ 0.5 Hydrophilic4-Hydroxyphenylacetic acid 0.2332 2.122 Ex. 1-46 SrCO₃ SrCO₃ 0.5Hydrophilic 3-(4-hydroxyphenyl)- 0.2332 2.122 propionic acid Comp. SrCO₃SrCO₃ 0.5 — 2.355 Ex. 1-3 Evaluation Dispersibility Treatment conditionsSolvent of Ex. Temp. Pressure Time Primary particles particle dispersion*2 Comp. Ex. ° C. MPa Min. Particle size Aspect ratio ChloroformCyclohexane Resin molded article *3 Optical film *4 Ex. 1-29 400 40 10SL: 0.14-0.21 μm 3-5 Dispersed as — Dispersed as primary Dispersed IL:0.4-1 μm primary particles particles as primary particles Ex. 1-30 30040 10 Dispersed as Dispersed as primary Dispersed primary particlesparticles as primary particles Ex. 1-31 300 30 10 Dispersed as Dispersedas primary Dispersed primary particles particles as primary particlesEx. 1-32 300 40 10 Dispersed as Dispersed as primary Dispersed primaryparticles particles as primary particles Ex. 1-33 300 30 10 Dispersed asDispersed as primary Dispersed primary particles particles as primaryparticles Ex. 1-34 300 40 10 Dispersed as Dispersed as primary Dispersedprimary particles particles as primary particles Ex. 1-35 400 40 10Dispersed as Dispersed as primary Dispersed primary particles particlesas primary particles Ex. 1-36 400 40 10 Dispersed as Dispersed asprimary Dispersed primary particles particles as primary particles Ex.1-37 300 30 10 Dispersed as Dispersed as primary Dispersed primaryparticles particles as primary particles Ex. 1-38 300 30 10 Dispersed asDispersed as primary Dispersed primary particles particles as primaryparticles Ex. 1-39 300 30 10 Dispersed as Dispersed as primary Dispersedprimary particles particles as primary particles Ex. 1-40 300 30 10Dispersed as Dispersed as primary Dispersed primary particles particlesas primary particles Ex. 1-41 300 30 10 Dispersed as Dispersed asprimary Dispersed primary particles particles as primary particles Ex.1-42 300 30 10 Dispersed as Dispersed as primary Dispersed primaryparticles particles as primary particles Ex. 1-43 400 40 10 Dispersed as— — primary particles Ex. 1-44 400 40 10 Dispersed as — — primaryparticles Ex. 1-45 400 40 10 Dispersed as — — primary particles Ex. 1-46400 40 10 Dispersed as — — primary particles Comp. 400 40 10 CoagulatedCoagulated Coagulated Ex. 1-3 *1: Negative birefringence *2: PreparationExample 1-1 *3: Production Example 1-1, Size: diameter of 10 mm,thickness of 5 mm *4: Production Example 1-2, Size: thickness of 20 μm

Example 1-47

Strontium carbonate (available from Honjo Chemical Corporation) in anamount of 0.5 g and oleic acid (available from Wako Pure ChemicalIndustries, Ltd.) in an amount of 3.5 mL were introduced into a 5 mLhigh-pressure reactor (available from AKICO Corporation).

Next, the high-pressure reactor was shaken for 15 minutes while heatingto 250° C. in a shaking furnace (available from AKICO Corporation),without closing the high-pressure reactor with a cover.

After heating, the high-pressure reactor was plunged into cold water forquenching.

Next, because oleic acid dissolves in ethanol, ethanol (available fromWako Pure Chemical Industries, Ltd.) was added, and the mixture wasstirred and subjected to centrifugal separation performed in acentrifuge (trade name: MX-301, available from Tomy Seiko Co., Ltd.) at12000 G for 10 minutes to separate a precipitate (reaction product) froma supernatant (washing step). By repeating this washing step 5 times,the remaining oleic acid was removed, and thereby particles wereobtained.

After that, the obtained particles were evaluated by (1) XRD, (2) FT-IRand (3) FE-SEM described above.

The formulation of respective components and the evaluation results inExample 1-47 are presented in Table 4, and an image-processed FE-SEMmicrograph in Example 1-47 is shown in FIG. 6.

As a result, (1) XDR confirmed that the inorganic compound forming theinorganic particles was SrCO₃.

(2) FT-IR confirmed C—H stretching vibrations from 2800 to 3000 cm⁻¹ andthe presence of C—H bonds on the surface of the inorganic particles.

(3) FE-SEM confirmed that the primary particles had an acicular shapewith a sideways length SL of approximately 140 to 210 nm and alengthwise length LL of approximately 400 nm to 1 μm with reference toFIG. 6. It was also confirmed that the aspect ratio of the primaryparticles was 3 to 5 as a result of calculation from FIG. 6.

Examples 1-48 to 1-54

Particles were obtained in the same manner as in Example 1-47 accordingto the formulation and treatment conditions presented in Table 4, andthen subjected to evaluation in the same manner as in Example 1-47. Theresults are presented in Table 4.

TABLE 4 Formulations Inorganic Carbonic acid pH adjusting agent PureComposition of compound Organic compound source Type (pH water Ex.inorganic Amount Hydrophobic/ Amount Amount of reaction Amount AmountComp. Ex. particles *1 Type (g) hydrophilic Type (mL) Type (mL) system)(mL) (mL) Ex. 1-47 SrCO₃ SrCO₃ 0.5 Hydrophobic Oleic acid 3.5 — — — Ex.1-48 SrCO₃ SrCO₃ 0.5 Hydrophobic Oleic acid 3.5 — Ex. 1-49 SrCO₃ SrCO₃0.5 Hydrophobic Oleic acid 3.5 — Ex. 1-50 SrCO₃ SrCO₃ 0.5 HydrophobicOleic acid 3.5 — Ex. 1-51 SrCO₃ SrCO₃ 0.5 Hydrophobic Oleic acid 3.5 —Ex. 1-52 SrCO₃ SrCO₃ 0.5 Hydrophobic Hexanoic acid 3.5 — Ex. 1-53 SrCO₃SrCO₃ 0.5 Hydrophobic Octanoic acid 3.5 — Ex. 1-54 SrCO₃ SrCO₃ 0.5Hydrophobic 3,3,5-Trimethylhexanoic 3.5 — acid Evaluation DispersibilityTreatment conditions Primary particles Solvent of particle Ex. Temp.Pressure Time Aspect dispersion *2 Resin molded Comp. Ex. ° C. MPa Min.Particle size ratio Chloroform Cyclohexane article *3 Optical film *4Ex. 1-47 250 0.1 15 SL: 0.14-0.21 μm 3-5 — Dispersed as Dispersed asDispersed as IL: 0.4-1 μm primary primary primary particles particlesparticles Ex. 1-48 150 15 Dispersed as Dispersed as Dispersed as primaryprimary primary particles particles particles Ex. 1-49 200 15 Dispersedas Dispersed as Dispersed as primary primary primary particles particlesparticles Ex. 1-50 250 4 Dispersed as Dispersed as Dispersed as primaryprimary primary particles particles particles Ex. 1-51 250 8 Dispersedas Dispersed as Dispersed as primary primary primary particles particlesparticles Ex. 1-52 150 15 Dispersed as Dispersed as Dispersed as primaryprimary primary particles particles particles Ex. 1-53 150 15 Dispersedas Dispersed as Dispersed as primary primary primary particles particlesparticles Ex. 1-54 150 15 Dispersed as Dispersed as Dispersed as primaryprimary primary particles particles particles *1: Negative birefringence*2: Preparation Example 1-1 *3: Production Example 1-1, Size: diameterof 10 mm, thickness of 5 mm *4: Production Example 1-2, Size: thicknessof 20 μm

Example 1-55 Synthesis Example 1-1 Synthesis of Titanium Complex

Under ice-cold conditions, 100 mL of 30 volume % hydrogen peroxidesolution and 25 mL of 25 wt % aqueous ammonia were added to a 500 mLbeaker. Furthermore, 1.5 g of titanium powder was added thereto and themixture was stirred under ice-cold conditions for 3 hours until completedissolution. Next, 15.5 g of 2-hydroxyoctanoic acid dissolved in 25 mLof ethanol was added and the mixture was stirred. After completedissolution of all components, stirring was stopped and the mixture wasallowed to stand still for one day. After that, the mixture was dried at75° C. in a drier for 3 hours so as to give a water-soluble titaniumcomplex (2-hydroxyoctanoic acid titanate).

(Preparation of Magnesium Titanate)

Magnesium hydroxide (available from Wako Pure Chemical Industries, Ltd.)in an amount of 0.0612 g, a titanium complex (Synthesis Example 1-1) inan amount of 0.5 g, decanoic acid (available from Wako Pure ChemicalIndustries, Ltd.) in an amount of 0.5181 mL and pure water in an amountof 2.098 mL were introduced into a 5 mL high-pressure reactor (availablefrom AKICO Corporation).

Next, the high-pressure reactor was closed with a cover, heated to 400°C. in a shaking furnace (available from AKICO Corporation) so as topressurize the inside of the high-pressure reactor to 40 MPa, and thenshaken for 10 minutes for hydrothermal synthesis.

After that, the high-pressure reactor was plunged into cold water forquenching.

Next, ethanol (available from Wako Pure Chemical Industries, Ltd.) wasadded, and the mixture was stirred and subjected to centrifugalseparation performed in a centrifuge (trade name: MX-301, available fromTomy Seiko Co., Ltd.) at 12000 G for 10 minutes to separate aprecipitate (reaction product) from a supernatant (washing step). Byrepeating this washing step 5 times, the remaining decanoic acid wasremoved, and thereby particles were obtained.

After that, the obtained particles were evaluated by (1) XRD, (2) FT-IRand (4) TEM described above.

The formulation of respective components and the evaluation results inExample 1-55 are presented in Table 5, and an image-processed TEMmicrograph in Example 1-55 is shown in FIG. 7.

As a result, (1) XDR confirmed that the inorganic compound forming theinorganic particles was magnesium titanate.

(2) FT-IR confirmed C—H stretching vibrations from 2800 to 3000 cm⁻¹ andthe presence of C—H bonds on the surface of the inorganic particles.

(4) TEM confirmed that the primary particles had an acicular shape witha sideways length SL of approximately 10 to 30 nm and a lengthwiselength LL of approximately 20 to 200 nm with reference to theimage-processed micrograph shown in FIG. 7. It was also confirmed thatthe aspect ratio of the primary particles was 2 to 20 as a result ofcalculation from the image-processed micrograph shown in FIG. 7.

Comparative Example 1-4

Magnesium hydroxide (available from Wako Pure Chemical Industries, Ltd.)in an amount of 0.0612 g, a titanium complex (Synthesis Example 1-1) inan amount of 0.5 g and pure water in an amount of 2.617 mL wereintroduced into a 5 mL high-pressure reactor (available from AKICOCorporation).

Next, the high-pressure reactor was closed with a cover, heated to 400°C. in a shaking furnace (available from AKICO Corporation) so as topressurize the inside of the high-pressure reactor to 40 MPa, and thenshaken for 10 minutes for hydrothermal synthesis.

After that, the high-pressure reactor was plunged into cold water forquenching.

Next, ethanol (available from Wako Pure Chemical Industries, Ltd.) wasadded, and the mixture was stirred and subjected to centrifugalseparation performed in a centrifuge (trade name: MX-301, available fromTomy Seiko Co., Ltd.) at 12000 G for 10 minutes and dried to giveparticles.

After that, the obtained particles were evaluated by (1) XRD, (2) FT-IRand (4) TEM described above.

The formulation of respective components and the evaluation results inComparative Example 1-4 are presented in Table 5, and an image-processedTEM micrograph in Comparative Example 1-4 is shown in FIG. 8.

As a result, (1) XDR confirmed that the inorganic compound forming theinorganic particles was magnesium titanate.

(2) FT-IR confirmed C—H stretching vibrations from 2800 to 3000 cm⁻¹ butthe presence of no C—H bonds on the surface of the inorganic particles.

(4) TEM confirmed that the primary particles had an acicular shape witha sideways length SL of approximately 20 to 30 nm and a lengthwiselength LL of approximately 30 to 200 nm. It was also confirmed that theaspect ratio of the primary particles was 1.5 to 10.

Comparative Examples 1-5 and 1-6

Particles were obtained in the same manner as in Example 1-4 accordingto the formulation and treatment conditions presented in Table 5, andthen subjected to evaluation in the same manner as in Example 1-4. Theresults are presented in Table 5.

Example 1-56

The particles obtained in Example 1-26 in an amount of 0.1 g andchloroform in an amount of 30 g were introduced into a 50 mL screw vial.

Next, the mixture was stirred with a spatula and allowed to stand stillfor one day, and thereby separated into a supernatant and a precipitate(sedimentation separation, wet classification).

Next, the supernatant was removed therefrom and dried to give particleshaving a small particle size.

After that, the obtained particles were evaluated by (1) XRD, (2) FT-IRand (3) FE-SEM described above.

The formulation of respective components and the evaluation results inExample 1-56 are presented in Table 5, and an image-processed FE-SEMmicrograph in Example 1-56 is shown in FIG. 9.

As a result, (1) XDR confirmed that the inorganic compound forming theinorganic particles was SrCO₃.

(2) FT-IR confirmed C—H stretching vibrations from 2800 to 3000 cm⁻¹ andthe presence of C—H bonds on the surface of the inorganic particles.

(3) FE-SEM confirmed that the primary particles had an acicular shapewith a sideways length SL of approximately 20 to 50 nm and a lengthwiselength LL of approximately 30 to 200 nm with reference to FIG. 9 andwere smaller than the particles of Example 1-26 (particles before wetclassification). It was also confirmed that the aspect ratio of theprimary particles was 1.5 to 10 as a result of calculation from FIG. 9.

TABLE 5 Formulations Inorganic Carbonic acid pH adjusting agent PureComposition compound Organic compound source Type (pH water Ex. ofinorganic Amount Hydrophobic Amount Amount of reaction Amount AmountComp. Ex. particles *1 Type (g) hydrophilic Type (mL) Type (mL) system)(mL) (mL) Ex. 1-55 MgTiO₃ Mg(OH)₂ 0.0612 Hydrophobic Decanoic acid0.5181 — — 2.098 Ti complex 0.5 Comp. Ex. 1-4 MgTiO₃ Mg(OH)₂ 0.0612 —2.617 Ti complex 0.5 Comp. Ex. 1-5 MgTiO₃ Mg(OH)₂ 0.0612 — 2.617 Ticomplex 0.55 Comp. Ex. 1-6 MgTiO₃ Mg(OH)₂ 0.0657 — 3.753 Ti complex 0.6Ex. 1-56 SrCO₃ (From Examples 1-26 (Wet classification) EvaluationDispersibility Treatment conditions Primary particles Solvent ofparticle Ex. Temp. Pressure Time Aspect dispersion *2 Resin molded Comp.Ex. ° C. MPa Min. Particle size ratio Chloroform Cyclohexane article *3Optical film *4 Ex. 1-55 400 40 10 SL: 10-30 nm  2-20 Dispersed as —Dispersed as Dispersed as IL: 20-200 nm primary primary primaryparticles particles particles Comp. Ex. 1-4 400 40 10 SL: 20-30 nm1.5-10 Coagulated Coagulated Coagulated IL: 30-200 nm Comp. Ex. 1-5 40040 120 SL: 20-30 nm 1.5-10 Coagulated Coagulated Coagulated IL: 30-200nm Comp. Ex. 1-6 300 30 120 SL: 20-30 nm 1.5-10 Coagulated CoagulatedCoagulated IL: 30-200 nm Ex. 1-56 (Wet classification) SL: 0.02-0.05 μm1.5-10 Dispersed as Uniformly Uniformly IL: 0.08-0.2 μm primarydispersed dispersed particles *1: Negative birefringence *2: PreparationExample 1-1 *3: Production Example 1-1, Size: diameter of 10 mm,thickness of 5 mm *4: Production Example 1-2, Size: thickness of 20 μm

Preparation Example 1-1 Preparation of Particle Dispersion

The particles obtained in Example 1-48 in an amount of 0.1 g andcyclohexane in an amount of 10 g were introduced into a 50 mL screw vialand stirred with a spatula to give a particle dispersion in which theparticles were dispersed in cyclohexane.

This particle dispersion was subjected to (5) particle size distributionmeasurement.

The obtained particle size distribution is shown in FIG. 10.

It was found out that the particle size distribution in FIG. 10 matchesthe particle size distribution in Example 1-48 (or in other words, theparticle size calculated from the sideways length SL and the lengthwiselength LL, average particle size: 400 nm).

Accordingly, it was confirmed that in the particle dispersion obtainedin Preparation Example 1-1, the particles were dispersed as primaryparticles in cyclohexane.

Also, the particles obtained in Examples 1-1 to 1-47, Examples 1-49 to1-56 and Comparative Examples 1-2 to 1-6 were used to prepare particledispersions in the same manner as described above. Next, the particledispersions were evaluated by (5) particle size distributionmeasurement.

As a result, in the particle dispersions prepared using the particlesobtained in Examples 1-1 to 1-47 and Examples 1-49 to 1-56, theparticles were dispersed as primary particles in cyclohexane orchloroform.

On the other hand, with the particle dispersions prepared using theparticles obtained in Comparative Examples 1-2 to 1-6, the particle sizedistribution measurement confirmed that the particles coagulatedtogether in cyclohexane or chloroform, forming secondary particles (withan average particle size of 0.8 μm or greater).

Production Example 1-1 Production of Resin Molded Article

The particles obtained in Example 1-36 in an amount of 0.5 g andchloroform in an amount of 4.5 g were introduced into a 100 mL screwvial and stirred with a spatula to give a particle dispersion A in whichthe particles were dispersed in chloroform.

Next, a resin solution in which polyarylate (Mw=60,000 to 80,000,softening temperature: 200° C.) in an amount of 4.5 g was dissolved in40.5 g of chloroform was mixed with the dispersion A to give aparticle-containing resin solution, and the particle-containing resinsolution was dried at 50° C. in a drier for one hour to removechloroform, and thereby a particle-dispersed resin composition wasobtained.

After that, the obtained particle-dispersed resin composition wasinjected into a metal mold having a diameter of 10 mm and a depth of 5mm and then molded by vacuum pressing under conditions of 200° C. and 60MPa to give a resin molded article.

The resin molded article was subjected to cross-section observation withthe (3) field emission-scanning electron microscope (FE-SEM).

FIG. 11 shows an image-processed FE-SEM micrograph of a cross section ofthe resin molded article in which the particles of Example 1-36 aredispersed.

As can be seen from FIG. 11, it was confirmed that the particles wereuniformly dispersed as primary particles in polyarylate.

The particles obtained in Examples 1-1 to 1-35, Examples 1-37 to 1-42,Examples 1-47 to 1-56 and Comparative Examples 1-2 to 1-6 were also usedto produce resin molded articles in the same manner as described above.Then, the resin molded articles were subjected to cross-sectionobservation with the (3) field emission-scanning electron microscope(FE-SEM).

FIG. 12 shows an image-processed FE-SEM micrograph of a cross section ofthe resin molded article in which the particles of Comparative Example1-2 are dispersed.

The result confirmed that, in the resin molded articles produced usingthe particles obtained in Examples 1-1 to 1-35, Examples 1-37 to 1-42,Examples 1-47 to 1-56, the particles were uniformly dispersed as primaryparticles in polyarylate.

On the other hand, it was confirmed that, in the resin molded articlesproduced using the particles of Comparative Examples 1-2 to 1-6, theparticles coagulated in polyarylate, forming secondary particles.

Production Example 1-2 Production of Optical Film

The particles obtained in Example 1-36 in an amount of 0.1 g andchloroform in an amount of 0.9 g were introduced into a 100 mL screwvial and stirred with a spatula to give a particle dispersion B in whichthe particles were dispersed in chloroform.

Next, a resin solution in which polyarylate (Mw=60,000 to 80,000,softening temperature: 200° C.) in an amount of 0.9 g was dissolved in8.1 g of chloroform was mixed with the dispersion B to give aparticle-dispersed resin solution, and the particle-dispersed resinsolution was applied to a support plate by spin coating and dried at 50°C. in a drier for one hour to remove chloroform, and thereby a coatingof particle-dispersed resin composition was obtained.

Subsequently, the obtained coating was dried at 100° C. for 10 minutesto give a 20 μm thick optical film.

The optical film was subjected to cross-section observation with the (3)field emission-scanning electron microscope (FE-SEM).

FIG. 13 shows an image-processed FE-SEM micrograph of a cross section ofthe optical film in which the particles of Example 1-36 are dispersed.

As can be seen from FIG. 13, it was confirmed that primary particleswere uniformly dispersed in polyarylate.

Also, the particles obtained in Examples 1-1 to 1-35, Examples 1-37 to1-42, Examples 1-47 to 1-56 and Comparative Examples 1-2 to 1-6 wereused to produce optical films in the same manner as described above.Next, the optical films were subjected to cross-section observation withthe (3) field emission-scanning electron microscope (FE-SEM).

FIG. 14 shows an image-processed FE-SEM micrograph of a cross section ofthe optical film in which the particles of Comparative Example 1-2 weredispersed.

The result confirmed that in the optical films produced using theparticles obtained in Examples 1-1 to 1-35, Examples 1-37 to 1-42 andExamples 1-47 to 1-56, the particles were uniformly dispersed as primaryparticles in polyarylate.

On the other hand, it was confirmed that in the optical films producedusing the particles of Comparative Examples 1-2 to 1-6, the particlescoagulated in polyarylate, forming secondary particles.

Preparation Examples and Examples Corresponding to the Second Group ofInventions

The second group of inventions will be described in further detail byshowing Preparation Examples and Examples, but the second group ofinventions is not limited thereto.

Evaluation methods performed on organic-inorganic composite particles,resins, solvents and films (particle-dispersed resin molded articles)will be described below.

(1) X-Ray Diffractometry (XRD)

Organic-inorganic composite particles were loaded into a glass holderand subjected to X-ray diffractometry under the following conditions.After that, from the obtained peaks, the components of the inorganicsubstance were assigned by database search.

X-ray diffractometer: D8 DISCOVER with GADDS, available from Bruker AXS

(Optical system on incident side)

X-ray source: CuKα (λ=1.542 Å), 45 kV, 360 mA

Spectroscope (monochromator): multilayer mirror

Collimator diameter: 300 μm

(Optical system on light-receiving side)

Counter: two-dimensional PSPC (Hi-STAR)

Distance between organic-inorganic composite particles and counter: 15cm

2θ=20, 50, 80 degrees, ω=10, 25, 40 degrees, Phi=0 degrees, Psi=0degrees

Measurement time: 10 minutes

Assignment (semiquantitation software): FPM EVA, available from BrukerAXS

(2) Fourier Transform Infrared Spectrophotometry (FT-IR)

Fourier transform infrared spectrophotometry was carried out onorganic-inorganic composite particles according to the KBr method usingthe following apparatus.

Fourier transform infrared spectrophotometer: FT/IR-470Plus, availablefrom JASCO Corporation

(3) Average Particle Size Measurement by Dynamic Light Scattering (DLS)

A sample (with a concentration of solids of 1 mass % or less) wasprepared by dispersing organic-inorganic composite particles in asolvent, and the average particle size of the organic-inorganiccomposite particles in the sample was measured with a dynamic lightscattering photometer (model: ZEN 3600, available from SysmexCorporation).

As the solvent, hexane was used in Preparation Example 2-1, chloroformwas used in Preparation Examples 2-2, 2-3 and 2-5 to 2-7, aqueousammonia having an ammonia concentration of 1 mass % was used inPreparation Example 2-4.

(4) Observation with Transmission Electron Microscope (TEM)

A film was cut, and its cross section was observed with a transmissionelectron microscope (TEM, H-7650, available from HitachiHigh-Technologies Corporation) for the dispersed state oforganic-inorganic composite particles.

Here, for a clear view of the cut surface of the film, the film wasembedded in epoxy resin before cutting (machining).

Also, a particle dispersion (with a concentration of solids of 1 mass %or less) obtained by diluting organic-inorganic composite particles witha solvent was applied dropwise onto a TEM grid (collodion film, carbonsupport film) and dried. Then, the organic-inorganic composite particleswere observed with a transmission electron microscope (TEM, H-7650,available from Hitachi High-Technologies Corporation) and the averageparticle size of the organic-inorganic composite particles wascalculated by image analysis.

(5) Clarity

Clarity of a film was visually observed.

Preparation of Organic-Inorganic Composite Particles: SecondHydrothermal Synthesis, Wet Classification Preparation Example 2-1

Cerium hydroxide (Ce(OH)₄, available from Wako Pure Chemical Industries,Ltd.) as an inorganic substance, decanoic acid and hexanoic acid asorganic compounds and water were introduced into a 5 mL high-pressurereactor (available from AKICO Corporation) in amounts presented in Table6.

Next, the high-pressure reactor was closed with a cover, heated to 400°C. in a shaking furnace (available from AKICO Corporation) so as topressurize the inside of the high-pressure reactor to 40 MPa, and thenshaken for 10 minutes for hydrothermal synthesis.

After that, the high-pressure reactor was plunged into cold water forquenching.

Next, ethanol (available from Wako Pure Chemical Industries, Ltd.) wasadded, and the mixture was stirred and subjected to centrifugalseparation performed in a centrifuge (trade name: MX-301, available fromTomy Seiko Co., Ltd.) at 12000 G for 20 minutes to separate into aprecipitate (reaction product) and a supernatant (washing step). Thiswashing operation was repeated 5 times. After that, ethanol in theprecipitate was heated and dried at 80° C. to give organic-inorganiccomposite particles in which a decyl group and a hexyl group werepresent on the surface of cerium oxide (CeO₂).

Next, the organic-inorganic composite particles obtained above andchloroform were introduced into a 50 mL centrifuge tube and subjected tocentrifugal separation in a centrifuge (trade name: MX-301, availablefrom Tomy Seiko Co., Ltd.) at 4000 G for 5 minutes to separate into asupernatant and a precipitate (wet classification).

Next, the supernatant was removed therefrom and dried to giveorganic-inorganic composite particles having a small average particlesize.

After that, the obtained organic-inorganic composite particles wereevaluated by (1) XRD, (2) FT-IR, (3) DLS and (4) TEM described above.

As a result, (1) XDR confirmed that the inorganic substance forming theinorganic particles was CeO₂.

Also, (2) FT-IR confirmed that there were saturated aliphatic groups (adecyl group and a hexyl group) on the surface of the inorganicparticles.

Furthermore, (3) DLS confirmed that the average particle size of theorganic-inorganic composite particles was 7 nm, and (4) TEM confirmedthat the average particle size of the organic-inorganic compositeparticles was 4 to 10 nm.

The above results are presented in Table 6.

Also, an image-processed TEM micrograph obtained by (4) TEM inPreparation Example 2-1 is shown in FIG. 15.

Preparation Examples 2-2 to 2-7

Organic-inorganic composite particles were prepared in the same manneras in Preparation Example 2-1, except that the formulation of theinorganic substance, the organic compound and water was changed to theformulations presented in Table 6, and the resulting organic-inorganiccomposite particles were subjected to wet classification.

After that, the obtained organic-inorganic composite particles wereevaluated in the same manner as in Preparation Example 2-1. The resultsare presented in Table 6.

TABLE 6 Formulations Inorganic substance Organic compound Pure waterPreparation Amount Amount Amount Example Type (g) Type (mL) Type Amount(mL) Pre. Ex. 2-1 Ce(OH)₄ 1.09 Decanoic acid 0.5181 Hexanoic acid 0.3279(mL) 1.771 Pre. Ex. 2-2 Ce(OH)₄ 1.09 6-Phenylhexanoic acid 0.4884Benzoic acid 0.3196 (g)   1.809 Pre. Ex. 2-3 Ce(OH)₄ 1.09 Decanoic acid1.0362 — 1.01 Pre. Ex. 2-4 Ti complex 0.5 10-Carboxydecyl 0.44 — 2.177phosphonate Pre. Ex. 2-5 Ti complex 0.5 Ethyl decylphosphonate 0.182Ethyl octylphosphonate 0.1638 (mL) 2.453 Pre. Ex. 2-6 SrCO₃ 0.56-Phenylhexanoic acid 0.3503 — 3.403 Pre. Ex. 2-7 BaSO₄ 0.56-Phenylhexanoic acid 0.3503 — 3.403 Organic-inorganic compositeparticles High-temperature treatment conditions Composition of AveragePreparation Synthesis Temp. Pressure Time inorganic particle Examplemethod ° C. MPa Min. particles *1 Organic group on surface *2 size (nm)*3 Pre. Ex. 2-1 Second 400 40 10 CeO₂ Decyl group Hexyl group  4-10hydrothermal [7] Pre. Ex. 2-2 synthesis 400 40 10 CeO₂ 6-Phenylhexylgroup Phenyl group 4-8 Pre. Ex. 2-3 400 40 10 CeO₂ Decyl group — 3-8Pre. Ex. 2-4 400 40 10 TiO₂ 10-Carboxydecyl group —  4-20 Pre. Ex. 2-5400 40 10 TiO₂ Decyl group Octyl group 4-8 Pre. Ex. 2-6 First 300 30 10SrCO₃ 6-Phenylhexyl group — 30-80 Pre. Ex. 2-7 hydrothermal 300 30 10BaSO₄ 6-Phenylhexyl group — 30-80 synthesis *1: Confirmed by XRD *2:Confirmed by FT-IR *3: Measured by TEM The value in square brackets wasmeasured by DLS

Preparation of Particle-Dispersed Resin Compositions (Fourth PreparationMethod) and Production of Films Example 2-1

A resin solution having a concentration of solids of 10 mass % wasprepared by blending polyetherimide resin (model: Ultem 1000, availablefrom SABIC Innovative Plastics Japan LLC) and chloroform.

Also, a particle dispersion having a concentration of solids of 10 mass% was prepared by blending the organic-inorganic composite particles ofPreparation Example 2-1 (inorganic substance: CeO₂, binding group:carboxyl group, organic groups: decyl group and hexyl group) andchloroform.

Next, the resin solution and the particle dispersion were blended suchthat the proportion of resin relative to the organic-inorganic compositeparticles in terms of mass was 90:10, and the organic-inorganiccomposite particles were dispersed in the resin solution by anultrasonic disperser. In this manner, a clear varnish ofparticle-dispersed resin composition was prepared.

Next, the obtained varnish was applied to a support plate by spincoating. Chloroform was mostly volatilized during application of thevarnish. After that, the applied particle-dispersed resin compositionwas dried at 50° C. for one hour (first drying) and then dried at 100°C. for 10 minutes (second drying) to give a 2.3 μm thick film(particle-dispersed resin molded article).

After that, the obtained film was evaluated by (4) TEM (the dispersedstate and average particle size of organic-inorganic compositeparticles) and (5) clarity described above. The results are presented inTable 6 (average particle size) and Table 7.

Also, an image-processed TEM micrograph obtained by (4) TEM in Example2-1 is shown in FIG. 16.

As can be seen from FIG. 16, there are gaps between organic-inorganiccomposite particles, and the organic-inorganic composite particles havea configuration that does not allow the inorganic particles to contactwith each other by steric hindrance of the organic groups.

Examples 2-2 to 2-14

Films were produced in the same manner as in Example 2-1, except thatthe formulation of the resin solution and the particle dispersion waschanged to the formulations presented in Table 7.

After that, the obtained films were evaluated in the same manner as inExample 2-1. The results are presented in Table 7.

Also, image-processed TEM micrographs obtained by (4) TEM in Examples2-2 to 2-4, 2-7, 2-8, 2-11, 2-13 and 2-14 are shown in FIGS. 17 to 24,respectively.

TABLE 7 Example • Comparative Example Ex. Ex. Ex. Ex. Ex. Ex. Ex. 2-12-2 2-3 2-4 2-5 2-6 2-7 Particle Organic- Prepara- Composition Organicgroup on surface Particle dispersed- inorganic tion of inorganicdispersion resin composite particles composition particles *1 ExampleSolvent (parts by Pre. Ex. CeO₂ Decyl group Hexyl Chloroform 10 10 10 30— — — mass) 2-1 group Pre. Ex. CeO₂ 6-Phenylhexyl Phenyl Chloroform — —— 10 20 10 10 2-2 group group Pre. Ex. CeO₂ Decyl group — Chloroform — —— — — — — 2-3 Pre. Ex. TiO₂ 10-Carboxydecyl — Aqueous — — — — — — — 2-410group ammonia *3 Pre. Ex. TiO₂ Decyl group Octyl Chloroform — — — — —— — 2-5 group Pre. Ex. SrCO₃ 6-Phenylhexyl — Chloroform — — — — — — —2-6 group Pre. Ex. BaSO₄ 6-Phenylhexyl — Chloroform — — — — — — — 2-7group Resin *2 Resin Resin (parts by solution mass) Solvent Pre. Ex.Polyether resin Chloroform 90 — — — 80 — — 2-8 Pre. Ex. Thermoplasticfluorine-based Chloroform — 90 — — — 90 — 2-9 polyimide resin Pre. Ex.Polyarylate Chloroform — — 90 60 — — 90 2-10 Pre. Ex. Polyvinyl alcoholresin Aqueous — — — — — — — 2-11 ammonia *3 Preparation method Fourthpreparation method Resin Evaluation TEM Dispersed state Uniformlydispersed as primary particles molded of organic- article inorganic(film) particles Visual inspection Clarity Clear Example • ComparativeExample Ex. Ex. Ex. Ex. Ex. Ex. Ex. 2-8 2-9 2-10 2-11 2-12 2-13 2-14Particle Organic- Prepara- Composition Organic group on surface Particledispersed- inorganic tion of inorganic dispersion resin compositeparticles composition particles *1 Example Solvent (parts by Pre. Ex.CeO₂ Decyl group Hexyl Chloroform — — — — — — — mass) 2-1 group Pre. Ex.CeO₂ 6-Phenylhexyl Phenyl Chloroform — — — — — — — 2-2 group group Pre.Ex. CeO₂ Decyl group — Chloroform 10 10 10 — — — — 2-3 Pre. Ex. TiO₂10-Carboxydecyl — Aqueous — — — 10 — — — 2-4 10group ammonia *3 Pre. Ex.TiO₂ Decyl group Octyl Chloroform — — — — 10 — — 2-5 group Pre. Ex.SrCO₃ 6-Phenylhexyl — Chloroform — — — — — 50 — 2-6 group Pre. Ex. BaSO₄6-Phenylhexyl — Chloroform — — — — — — 50 2-7 group Resin *2 Resin Resin(parts by solution mass) Solvent Pre. Ex. Polyether resin Chloroform 90— — — — — — 2-8 Pre. Ex. Thermoplastic fluorine-based Chloroform — 90 —— — — — 2-9 polyimide resin Pre. Ex. Polyarylate Chloroform — — 90 90 5050 2-10 Pre. Ex. Polyvinyl alcohol resin Aqueous — — — 90 — — — 2-11ammonia *3 Preparation method Fourth preparation method Resin EvaluationTEM Dispersed state Uniformly dispersed as primary particles molded oforganic- article inorganic (film) particles Visual inspection ClarityClear *1: Blended as particle dispersion, with concentration of solids(organic-inorganic composite particles) of 10 mass % *2: Blended asresin solution, with concentration of solids (resin) of 10 mass % *3:Ammonia concentration of 1 mass %

In Table 7, the numerical values provided in “Organic-inorganiccomposite particles” and “Resin” indicate the amounts expressed in partsby mass. Also, the following gives detailed description of resins.

Polyetherimide resin: Ultem 1000, available from SABIC InnovativePlastics Japan LLC

Thermoplastic fluorine-based polyimide resin: thermoplasticfluorine-based polyimide resin used in Example 1 of Japanese UnexaminedPatent Publication No. 2003-315541

Polyarylate: polyarylate resin used in Example 4 of Japanese UnexaminedPatent Publication No. 2009-80440

Polyvinyl alcohol resin: JC-40, available from Japan VAM & Poval Co.,Ltd.

Preparation Examples, Examples, Comparative Examples and the LikeCorresponding to the Third Group of Inventions

The present invention will be described below in further detail byshowing Preparation Examples, Examples and Comparative Examples, but thepresent invention is not limited thereto.

The evaluation methods for catalyst particles, catalyst solutions andfilms (catalyst molded articles) will be described below.

<Evaluation Methods> (1) X-Ray Diffractometry (XRD)

Catalyst particles were loaded into a glass holder and subjected toX-ray diffractometry under the following conditions. After that, fromthe obtained peaks, the components of the inorganic compound wereassigned by database search.

X-ray diffractometer: D8 DISCOVER with GADDS, available from Bruker AXS

(Optical system on incident side)

X-ray source: CuKα (λ=1.542 Å), 45 kV, 360 mA

Spectroscope (monochromator): multilayer mirror

Collimator diameter: 300 μm

(Optical system on light-receiving side)

Counter: two-dimensional PSPC (Hi-STAR)

Distance between catalyst particles and counter: 15 cm 2θ=20, 50, 80degrees, ω=10, 25, 40 degrees, Phi=0 degrees, Psi=0 degrees

Measurement time: 10 minutes

Assignment (semiquantitation software): FPM EVA, available from BrukerAXS

(2) Fourier Transform Infrared Spectrophotometry (FT-IR)

Fourier transform infrared spectrophotometry was carried out on catalystparticles according to the KBr method using the following apparatus.

Fourier transform infrared spectrophotometer: FT/IR-470Plus, availablefrom JASCO Corporation

(3) Average Particle Size Measurement A. DLS (Dynamic Light Scattering)

A sample (catalyst solution with a concentration of solids of 1 mass %or less) was prepared by dispersing catalyst particles in a solvent, andthe average particle size of the catalyst particles in the sample wasmeasured with a dynamic light scattering photometer (model: ZEN 3600,available from Sysmex Corporation).

B. SEM (Scanning Electron Microscope)

A catalyst solution was applied dropwise onto a sample stage and dried.Then, the average particle size of catalyst particles was observed byobservation with a scanning electron microscope (S-4800 available fromHitachi High-Technologies Corporation or JSM-7001F available from JEOLLtd.).

C. TEM (Transmission Electron Microscope)

A sample (catalyst solution with a concentration of solids of 1 mass %or less) obtained by diluting catalyst particles with a solvent wasapplied dropwise onto a TEM grid (collodion film, carbon support film)and dried. Then, the catalyst particles were observed with atransmission electron microscope (TEM, H-7650, available from HitachiHigh-Technologies Corporation) and the average particle size of catalystparticles was calculated by image analysis.

D. XRD

The average particle size of catalyst particles was calculated bysubstituting the data obtained in (1) XRD above into the followingScherrer's equation (2).

D=Kλ/(β cos θ),  (2)

where D is the average crystalline particle size, K is the Scherrerconstant, λ is the wavelength of the X-ray tube, β is the half bandwidth, and θ is the diffraction angle.

(4) Evaluation of Catalytic Action A. Examples 3-1 to 3-78 andComparative Examples 3-1 to 3-5

An aqueous solution containing 0.01 mass % of rhodamine B (rhodamine Bwith a molecular weight of 479.01) was prepared (0.02 m mol/L).

Next, 0.01 g of catalyst particles of each of Examples 3-1 to 3-78 andComparative Examples 3-1 to 3-5 were added to a transparent 2 mL vialand thereafter 1 g of the prepared aqueous solution of rhodamine B wasadded thereto.

After that, in a dark room, the vial was irradiated with black light(ultraviolet rays with a wavelength of 365 nm) at an illuminance of 1mW/cm² for one hour.

After that, the aqueous solution of rhodamine B in the vial wassubjected to ultraviolet-visible absorption spectrometry. Thespectrometry was carried out with an ultraviolet-visible absorptionspectrometer (U-560, available from JASCO Corporation).

Then, whether the catalyst particles exerted a catalytic action wasevaluated based on the following evaluation criteria.

A circle “∘” was given when a peak (wavelength: 550 nm) derived fromrhodamine B disappeared.

A cross “x” was given when a peak (wavelength: 550 nm) derived fromrhodamine B remained.

FIGS. 25 and 26 each show UV-visible absorption spectra at the start ofirradiation and after a predetermined period of time has passed,obtained in Examples 3-10 and 3-66.

B. Examples 3-79 to 3-83 and Comparative Examples 3-6 to 3-13

One mol/L of aqueous acetaldehyde solution was prepared.

Next, 0.1 g of catalyst particles obtained in each of Examples 3-79 to3-83 and Comparative Examples 3-6 to 3-13 was added to a vial (10 mL),and then the prepared aqueous acetaldehyde solution was added thereto inan amount of 100 μL with a syringe. After that, a septum cap was placedon the opening of the vial and the whole was stirred well.

After that, the vial was irradiated with light for 30 minutes using a300 W xenon lamp (Cermax LX-300, available from Perkin Elmer Inc.). Acutoff filter (HOYA L42, available from HOYA) was attached to the xenonlamp to shield (shade) ultraviolet light (ultraviolet light with awavelength of 420 nm or less).

After that, the concentration of CO₂ produced by decomposition offormaldehyde in the vial was measured by gas chromatography (HP 5890Series II plus/HP5972, column: Ultra-1 (0.2 φ×25 m, df=0.33 um),available from Agilent Technologies, Inc.).

Then, whether the catalyst particles exerted a catalytic action wasevaluated based on the following evaluation criteria.

A circle “∘” was given when the CO₂ concentration was 10 ppm or greater.

A cross “x” was given when the CO₂ concentration was less than 10 ppm.

(5) Evaluation of Resin Degradation

A white film (described later) on which catalyst particles had beendispersed was heated at 80° C. in a drier for hour. After that, the filmwas irradiated with black light (ultraviolet rays with a wavelength of365 nm) at an illuminance of 1 mW/cm² for 24 hours.

After that, degradation of the film was visually observed and evaluatedbased on the following evaluation criteria.

A circle “∘” was given when the film was white.

A cross “x” was given when the film was yellow.

Preparation of Titanium Complex Preparation Example 3-1 Preparation ofTitanium Complex Containing 2-Hydroxyoctanoic Acid as Ligand

Under ice-cold conditions, 100 mL of 30 volume % hydrogen peroxidesolution and 25 mL of 25 wt % aqueous ammonia were added to a 500 mLbeaker. Furthermore, 1.5 g of titanium powder was added thereto and themixture was stirred under ice-cold conditions for 3 hours until completedissolution. Next, 15.5 g of 2-hydroxyoctanoic acid dissolved in 25 mLof ethanol was added and the mixture was stirred. After completedissolution of all components, stirring was stopped and the mixture wasallowed to stand still for one day. After that, the mixture was dried at75° C. in a drier for 3 hours so as to give a water-soluble titaniumcomplex.

This titanium complex was used as a complex (see Tables 8, 10 to 14 and16) in Examples 3-8 to 3-17, 3-31 to 3-68, 3-78 and Comparative Example3-3, which will be described later.

Preparation Example 3-2 Preparation of Titanium Complex ContainingGlycolic Acid as Ligand

A water-soluble titanium complex was obtained through the same treatmentas in Preparation Example 3-1, except that 3.6 g of glycolic acid wasadded instead of 15.5 g of 2-hydroxyoctanoic acid.

The titanium complex was used as a complex (see Table 9) in Example3-21, which will be described later.

Preparation Example 3-3 Preparation of Titanium Complex ContainingCitric Acid as Ligand

A water-soluble titanium complex was obtained through the same treatmentas in Preparation Example 3-1, except that 9.1 g of citric acid wasadded instead of 15.5 g of 2-hydroxyoctanoic acid.

This titanium complex was used as a complex (see Table 9) in Examples3-18 to 3-20, which will be described later.

Preparation Example 3-4 Preparation of Titanium Complex Containing MalicAcid as Ligand

A water-soluble titanium complex was obtained through the same treatmentas in Preparation Example 3-1, except that 6.3 g of malic acid was addedinstead of 15.5 g of 2-hydroxyoctanoic acid.

This titanium complex was used as a complex (see Table 9) in Example3-22, which will be described later.

Preparation of Catalyst Particles Examples 3-1 to 3-83 and ComparativeExamples 3-1 to 3-13

Respective components (an inorganic substance and/or a complex, anorganic compound, a pH adjusting agent and water) were introduced into a5 mL high-pressure reactor (available from AKICO Corporation) accordingto the formulation presented in Tables 8 to 16.

Next, the high-pressure reactor was closed with a cover and treated in ashaking furnace (available from AKICO Corporation) under the hightemperature treatment conditions presented in Tables 8 to 16.

After that, the high-pressure reactor was plunged into cold water forquenching.

Next, ethanol (available from Wako Pure Chemical Industries, Ltd.) wasadded and the mixture was stirred. Subsequently, the mixture wassubjected to centrifugal separation performed in a centrifuge (tradename: MX-301, available from Tomy Seiko Co., Ltd.) at 12000 G for 20minutes to separate a precipitate (reaction product) from a supernatant(washing step). This washing operation was repeated 5 times.

After that, ethanol in the precipitate was heated and dried at 80° C. togive catalyst particles.

After that, the obtained catalyst particles were evaluated by (1) XRD,(2) FT-IR, (3) average particle size and (4) catalytic action describedabove.

As a result, (1) XRD confirmed that the primary components of theinorganic particles were TiO₂ (Examples 3-1 to 3-71 and ComparativeExamples 3-1 to 3-5), WO₃ (Examples 3-72 to 3-75 and ComparativeExamples 3-6 to 3-13) and SrTiO₃ (Examples 3-76 to 3-83).

Also, (2) FT-IR confirmed that there were organic groups that arepresented in Table 8 to 16 on the surface of the inorganic particles.

(3) Average particle size measurement showed that, as is clear fromTables 8 to 16, the average particle size of catalyst particles of eachof Examples 3-1 to 3-83 was 450 nm or less.

Also, it was found out, from the fact that peaks derived from rhodamineB disappeared in Examples 3-1 to 3-78 and Comparative Examples 3-1 to3-5, and CO₂ was produced by decomposition of formaldehyde in Examples3-79 to 3-83 and Comparative Examples 3-6 to 3-13, that the catalystparticles of Examples 3-1 to 3-83 and Comparative Examples 3-1 to 3-13exerted an action of decomposing organic substances (photocatalyticaction).

<Production of Catalyst Molded Articles>

A resin solution having a concentration of solids of 10 mass % wasprepared by blending polyarylate (polyarylate resin used in Example 4 ofJapanese Unexamined Patent Publication No. 2009-80440) with chloroformand uniformly mixing them.

Besides this, a catalyst solution having a concentration of solids of 10mass % was prepared by blending catalyst particles of each of Examples3-1 to 3-83 and Comparative Examples 3-1 to 3-13 with chloroform anduniformly mixing them.

Next, the resin solution and the catalyst solution were blended suchthat the proportion of resin relative to catalyst particles in terms ofmass was 90:10 (the amount of resin expressed in parts by mass: theamount of catalyst particles expressed in parts by mass), and thecatalyst particles were dispersed in the resin solution using anultrasonic disperser. In this manner, a clear varnish of catalystcomposition was prepared.

Next, the obtained varnish of catalyst composition was applied to asupport plate by spin coating. Chloroform was mostly volatilized duringapplication of the varnish. After that, the applied catalyst compositionwas dried at 50° C. for one hour (first drying) and then dried at 100°C. for 10 minutes (second drying) to give a film containing catalystparticles (catalyst molded article).

After that, the obtained films were evaluated by (5) resin degradationevaluation.

The results are presented in Tables 8 to 16.

As can be seen from Tables 8 to 16, the evaluation of resin degradationshowed that polyarylate resin forming the films of Comparative Examples3-1 to 3-13 degraded because the films yellowed.

On the other hand, in each of Examples 3-1 to 3-83, degradation ofpolyarylate resin was suppressed because the films remained white ortransparent/colorless, without any discoloration.

In the tables, each numerical value within parentheses “( )” provided in“Formulation” indicates the volume expressed in mL, and other numericalvalues, or in other words, the numerical values without parenthesesindicate the mass expressed in g.

Also, in “Average particle size” in the tables, each numerical valuewithin square brackets “[ ]” indicates the average particle sizecalculated through TEM or SEM image analysis, each numerical valuewithin angle brackets “< >” indicates the average particle sizecalculated with the Scherrer's equation based on the data obtained byXRD, and other numerical values, or in other words, the numerical valueswithout brackets indicate the average particle size measured by DLS.

The following gives detailed description of TiO₂ used in Examples 3-1 to3-7 and 3-30.

TiO₂ used in Examples 3-1 and 3-2: average particle size 7 nm, tradename CSB-M, available from Sakai Chemical Industry Co., Ltd.

TiO₂ used in Examples 3-3 and 3-30: average particle size 9 nm, tradename SSP-25, available from Sakai Chemical Industry Co., Ltd.

TiO₂ used in Examples 3-4 and 3-5: minor diameter 5 to 15 nm, majordiameter 30 to 90 nm, trade name TTO-V-3, available from Ishihara SangyoKaisha, Ltd.

TiO₂ used in Example 3-6: average particle size 30 to 50 nm, TTO-55(A),available from Ishihara Sangyo Kaisha, Ltd.

TiO₂ used in Example 3-7: average particle size 10 to 30 nm, TTO-51(A),available from Ishihara Sangyo Kaisha, Ltd.

TABLE 8 Formulations High-temperature Inorganic substance treatmentconditions and/or complex Organic compound Surface Amount Amount Watertreatment Temp. g(mL) g(mL) mL method ° C. Ex. 3-1 TiO₂ 0.5Decylphosphonic acid 0.364 2.253 First 400 diethyl ester hydrothermalEx. 3-2 0.5 10-(Diethoxy- 0.440 2.177 synthesis 400 phosphonyl)decanoicacid ethyl ester Ex. 3-3 0.5 Decylphosphonic acid 0.364 2.253 400diethyl ester Ex. 3-4 0.04 Decylphosphonic acid 0.023 2.070 400 Ex. 3-50.5 0.291 2.326 400 Ex. 3-6 0.5 0.291 2.326 400 Ex. 3-7 0.5Octylphosphonic acid 0.328 2.289 400 diethyl ester Ex. 3-8 Ti complex0.1 6-Phosphonic hexanoic acid 0.257 2.360 Second 400 Ex. 3-9 (ligand:0.5 Decylphosphonic acid 0.197 4.226 hydrothermal 200 Ex. 3-102-hydroxyoctanoic 0.5 0.291 2.326 synthesis 400 Ex. 3-11 acid) 0.5Methylphosphonic acid 0.144 2.473 400 Ex. 3-12 0.5 3-Phosphonopropionicacid 0.202 1.915 400 Ex. 3-13 0.5 10-(Diethoxy- 0.422 2.195 400phosphonyl)decanol Ex. 3-14 0.5 Decylphosphonic acid 0.364 2.253 400diethyl ester Ex. 3-15 0.5 10-(Diethoxy- 0.440 2.177 400phosphonyl)decanoic acid ethyl ester Ex. 3-16 0.5 Octylphosphonic acid0.328 2.289 400 Ex. 3-17 0.6 diethyl ester 0.282 3.472 300High-temperature Catalyst particles treatment conditions AverageReaction particle Evaluation Pressure time Inorganic Organic group sizePhotocatalytic Resin MPa Min. particles on surface nm action degradationEx. 3-1 40 10 TiO₂ Decyl <7> ◯ ◯ Ex. 3-2 40 10 9-Carboxynonly <7> ◯ ◯Ex. 3-3 40 10 Decyl <9> ◯ ◯ Ex. 3-4 40 10  [5 to 15] ◯ ◯ Ex. 3-5 40 10 [5 to 15] ◯ ◯ Ex. 3-6 40 10 [30 to 50] ◯ ◯ Ex. 3-7 40 10 Octyl [10 to30] ◯ ◯ Ex. 3-8 40 10 5-Carboxypentyl ◯ ◯ Ex. 3-9 30 10 Decyl  [1 to 10]◯ ◯ Ex. 3-10 40 10 [2 to 8] ◯ ◯ Ex. 3-11 40 10 Methyl ◯ ◯ Ex. 3-12 40 102-Carboxyethyl  [3 to 50] ◯ ◯ Ex. 3-13 40 10 10-Hydroxydecyl [3 to 7] ◯◯ Ex. 3-14 40 10 Decyl [2 to 8] ◯ ◯ Ex. 3-15 40 10 9-Carboxynonyl  [4 to20] ◯ ◯ Ex. 3-16 40 10 Octyl [2 to 8] ◯ ◯ Ex. 3-17 30 120 — ◯ ◯

TABLE 9 Formulations Inorganic-substance and/or complex Organic compoundpH adjusting agent Amount Amount Amount Water g(mL) g(mL) mL mL Ex. 3-18Ti complex (ligand: 0.5 Decylphosphonic acid 0.556 — 1.944 Ex. 3-19citric acid) 0.5 6-Phosphonohexanoic acid 0.490 2.010 Ex. 3-20 0.510-(Diethoxy-phosphonyl)decanoic 0.841 1.659 acid ethyl ester Ex. 3-21Ti complex (ligand: 0.5 Decylphosphonic acid 0.440 2.177 glycolic acid)diethyl ester Ex. 3-22 Ti complex (ligand: 0.1 Decylphosphonic acid0.291 2.326 malic acid) Ex. 3-23 10 wt % aqueous 2.2523 Decylphosphonicacid 0.364 — amorphous diethyl ester TiO₂ solution Ex. 3-24 Titanium0.2093 0.364 0.4M aqueous (2.044) — sulfate KOH solution Ex. 3-25Ammonium oxalate 0.5 Octylphosphonic acid 0.328 — 2.289 monohydratediethyl ester Ex. 3-26 50 wt % aqueous titanium (1) 0.328 1.289 Ex. 3-27(IV) bis(ammonium (1) 10-(Diethoxy-phosphonyl)decanoic 0.733 2.622 Ex.3-28 lactato)dihydroxide (2) acid ethyl ester 0.440 1.915 Ex. 3-29solution (2) 0.632 0.945 Catalyst particles High-temperature treatmentconditions Average Surface Reaction Organic particle Evaluationtreatment Temp. Pressure time Inorganic group on size PhotocatalyticResin method ° C. MPa Min. particles surface nm action degradation Ex.3-18 Second 400 40 10 TiO₂ Decyl — ◯ ◯ Ex. 3-19 hydrothermal 400 40 105-Carboxypentyl — ◯ ◯ Ex. 3-20 synthesis 400 40 10 9-Carboxynonyl — ◯ ◯Ex. 3-21 400 40 10 Decyl [2 to 8]  ◯ ◯ Ex. 3-22 400 40 10 [8 to 40] ◯ ◯Ex. 3-23 First 400 40 5 — ◯ ◯ hydrothermal synthesis Ex. 3-24 Second 40040 10 — ◯ ◯ Ex. 3-25 hydrothermal 400 40 10 Octyl [30]  ◯ ◯ Ex. 3-26synthesis 400 40 10 [5] ◯ ◯ Ex. 3-27 200 10 10 9-Carboxynonyl [3] ◯ ◯Ex. 3-28 200 10 10 [3] ◯ ◯ Ex. 3-29 300 10 10 [5] ◯ ◯

TABLE 10 Formulations Inorganic substance and/or complex Organiccompound Amount Amount Amount Amount Water g(mL) g(mL) g(mL) g(mL) mLEx. 3-30 TiO₂ 0.5 Octylphosphonic 0.164 Decylphosphonic 0.182 — 2.357acid diethyl ester acid diethyl ester Ex. 3-31 Ti complex 0.13-(Diethoxy- 0.156 6-(Diethoxy-phos- 0.176 2.284 (ligand:phosphonyl)ethyl phonyl)hexanoic 2-hydroxy- propionic acid ethyl esteroctanoic acid ester Ex. 3-32 acid) 0.1 3-Phosphono- 0.0206-Phosphonohexanoic 0.026 2.571 propionic acid acid Ex. 3-33 0.1 0.03110-(Diethoxy-phos- 0.044 2.541 phonyl)decanoic acid ethyl ester Ex. 3-340.1 Octylphosphonic 0.033 10-(Diethoxy-phos- 0.044 2.540 acid diethylester phonyl)decanoic acid ethyl ester Ex. 3-35 0.1 0.131Decylphosphonic 0.146 10-(Diethoxy-phos- 0.176 2.164 acid diethyl esterphonyl)decanoic acid ethyl ester Ex. 3-36 0.1 Methylphosphonic 0.01310-(Diethoxy-phos- 0.044 — 2.560 acid phonyl)decanoic acid ethyl esterEx. 3-37 0.1 0.013 6-Phosphonohexanoic 0.026 2.578 acid High-temperaturetreatment conditions Catalyst particles Reac- Average Evaluation SurfacePres- tion particle Photo- Resin treatment Temp. sure time Inorganicsize catalytic degra- method ° C. MPa Min. particles Organic group onsurface nm action dation Ex. 3-30 First 400 40 10 TiO₂ Octyl Decyl — <9>◯ ◯ hydrothermal synthesis Ex. 3-31 Second 400 40 10 2-Carboxyethyl5-Carboxypentyl [2 to 10] ◯ ◯ Ex. 3-32 hydrothermal 400 40 102-Carboxyethyl 5-Carboxypentyl [4 to 16] ◯ ◯ Ex. 3-33 synthesis 400 4010 9-Carboxynonyl [4 to 8]  ◯ ◯ Ex. 3-34 400 40 10 Octyl [4 to 15] ◯ ◯Ex. 3-35 400 40 10 Decyl 9-Carboxynonyl [2 to 10] ◯ ◯ Ex. 3-36 400 40 10Methyl 9-Carboxynonyl — [4 to 24] ◯ ◯ Ex. 3-37 400 40 10 5-Carboxypentyl[4 to 14] ◯ ◯

TABLE 11 Formulations High-temperature Inorganic substance treatmentconditions and/or complex Organic compound Surface Amount Amount AmountAmount Water treatment Temp. g(mL) g(mL) g(mL) g(mL) mL method ° C. Ex.3-38 Ti complex 0.4 Octylphos- 0.131 Decylphos- 0.1164 10-(Diethoxy-0.088 2.369 Second 400 Ex. 3-39 (ligand: 0.4 phonic 0.131 phonic 0.1164phospho- 0.176 2.193 hydrothermal 400 Ex. 3-40 2-hydroxy- 0.4 aciddiethyl 0.197 acid 0.0582 nyl)decanoic 0.176 2.617 synthesis 400octanoic ester acid ethyl acid) ester Ex. 3-41 0.4 Methyl- 0.072Octylphos- 0.131 10-(Diethoxy- 0.176 2.238 400 phosphonic phonicphospho- acid acid diethyl nyl)decanoic ester acid ethyl ester Ex. 3-420.4 0.115 3-Phosphono- 0.046 — 2.841 300 propionic acid Ex. 3-43 0.40.115 6-Phosphono- 0.059 2.828 300 hexanoic acid Ex. 3-44 0.5 Octylphos-0.131 Decylphos- 0.1164 10-(Diethoxy- 0.088 2.281 400 Ex. 3-45 0.5phonic 0.131 phonic 0.1164 phospho- 0.088 2.369 400 Ex. 3-46 0.5 aciddiethyl 0.131 acid 0.1164 nyl)decanoic 0.176 2.193 400 ester acid ethylester Ex. 3-47 0.5 0.164 10-(Diethoxy- 0.220 — 2.233 400 phospho-nyl)decanoic acid ethyl ester Ex. 3-48 0.5 0.164 Decylphos- 0.182 2.453400 phonic acid Ex. 3-49 0.5 0.262 10-(Diethoxy- 0.088 2.267 400phospho- nyl)decanoic acid ethyl ester High-temperature treatmentconditions Catalyst particles Reac- Average Evaluation Pres- tionparticle Photo- Resin sure time Inorganic size catalytic degra- MPa Min.particles Organic group on surface nm acton dation Ex. 3-38 40 10 TiO₂Octyl Decyl 9-Carboxynonyl 10 ◯ ◯ Ex. 3-39 40 10 [3 to 12] ◯ ◯ Ex. 3-4040 10 [2 to 14] ◯ ◯ Ex. 3-41 40 10 Methyl Octyl 9-Carboxynonyl [3 to 40]◯ ◯ Ex. 3-42 30 10 2-Carboxyethyl — [3 to 40] ◯ ◯ Ex. 3-43 30 105-Carboxypentyl [2 to 30] ◯ ◯ Ex. 3-44 40 10 Octyl Decyl 9-Carboxynonyl20 ◯ ◯ Ex. 3-45 40 10 20 ◯ ◯ Ex. 3-46 40 10 [2 to 40] ◯ ◯ Ex. 3-47 40 109-Carboxynonyl — — ◯ ◯ Ex. 3-48 40 10 Decyl [4 to 8]  ◯ ◯ Ex. 3-49 40 109-Carboxynonyl [4 to 8]  ◯ ◯

TABLE 12 Formulations Inorganic substance and/or complex Organiccompound Amount Amount Amount Amount Amount Water g(mL) g(mL) g(mL)g(mL) g(mL) mL Ex. 3-50 Ti complex 0.5 — Octylphosphonic 0.262Decylphos- 0.0582 10-(Diethoxy- 0.088 2.296 (ligand: acid diethyl phonicphospho- 2-hydroxy- ester acid nyl)decanoic octanoic acid ethyl acid)ester Ex. 3-51 0.5 0.295 10-(Diethoxy- 0.044 — 2.278 phospho-nyl)decanoic acid ethyl ester Ex. 3-52 0.5 Pt 0.001 0.256 — 2.194 Ex.3-53 0.5 — Methylphosphonic 0.072 10-(Diethoxy- 0.088 Decylphos- 0.11642.340 acid phospho- phonic nyl)decanoic acid acid ethyl ester Ex. 3-540.5 0.144 0.038 0.0582 2.326 Ex. 3-55 0.5 0.144 3-Phosphono- 0.040Octylphosphonic 0.0655 2.407 propionic acid diethyl acid ester Ex. 3-560.5 0.144 6-Phosphono- 0.051 0.0655 2.407 hexanoic acid Ex. 3-57 0.13-(Diethoxy- 0.031 3-(Diethoxy- 0.035 — 2.550 phospho- phospho-nyl)ethyl nyl)ethyl propionic propionic acid ester acid ester Ex. 3-580.1 3-Phosphono- 0.020 6-Phosphono- 0.026 2.571 propionic hexanoic acidacid Ex. 3-59 0.5 Methylphosphonic 0.063 Decylphos- 0.146 2.560 acidphonic acid High-temperature treatment conditions Catalyst particlesReac- Average Evaluation Surface Pres- tion particle Photo- Resintreatment Temp. sure time Inorganic size catalytic degra- method ° C.MPa Min. particles Organic group on surface nm action dation Ex. 3-50Second 400 40 10 TiO₂ Octyl Decyl 9-Carboxynonyl [4 to 13] ◯ ◯ Ex. 3-51hydrothermal 400 40 10 9-Carboxynonyl — [4 to 8]  ◯ ◯ Ex. 3-52 synthesis400 40 10 TiO₂/Pt — — ◯ ◯ Ex. 3-53 400 40 10 TiO₂ Methyl 9-CarboxynonylDecyl [4 to 12] ◯ ◯ Ex. 3-54 400 40 10 — ◯ ◯ Ex. 3-55 400 40 102-Carboxyethyl Octyl — ◯ ◯ Ex. 3-56 400 40 10 5-Carboxypentyl — ◯ ◯ Ex.3-57 400 400 10 2-Carboxyethyl 5-Carboxypentyl — [2 to 10] ◯ ◯ Ex. 3-58400 40 10 2-Carboxyethyl 5-Carboxypentyl [2 to 10] ◯ ◯ Ex. 3-59 400 4010 Methyl Decyl [4 to 18] ◯ ◯

TABLE 13 Formulations Inorganic substance and/or complex Organiccompound pH adjusting agent Amount Amount Amount Amount Amount Waterg(mL) g(mL) g(mL) g(mL) g(mL) mL Ex. 3-60 Ti complex 0.5 3-(Diethoxy-0.0623 Decylphos- 0.218 10-(Diethoxy- 0.088 — 2.248 (ligand: phospho-phonic phospho- 2-hydroxy- nyl)ethyl acid diethyl nyl)decanoic octanoicpropionic ester acid ethyl acid) acid ester ester Ex. 3-61 0.53-(Diethoxy- 0.125 10-(Diethoxy- 0.176 — 2.316 phospho- phospho-nyl)ethyl nyl)decanoic propionic acid ethyl acid ester ester Ex. 3-620.5 Octylphosphonic 0.6555 Decylphos- 0.073 10-(Diethoxy- 0.176 2.302Ex. 3-63 0.5 acid diethyl 0.6555 phonic 0.073 phospho- 0.264 2.214 Ex.3-64 0.5 ester 0.131 acid diethyl 0.146 nyl)decanoic 0.176 2.164 esteracid ethyl ester Ex. 3-65 0.5 0.164 Decylphos- 0.146 — 2.453 phonic acidEx. 3-66 0.5 0.164 Decylphos- 0.182 2.453 phonic acid diethyl Ex. 3-670.5 0.164 0.182 2.271 Ex. 3-68 0.5 0.164 0.182 1% (2.271) — Aqueousammonia High-temperature treatment conditions Catalyst particles Reac-Average Evaluation Surface Pres- tion particle Photo- Resin treatmentTemp. sure time Inorganic size catalytic degra- method ° C. MPa Min.particles Organic group on surface nm action dation Ex. 3-60 Second 40040 10 TiO₂ 2-Carboxyethyl Decyl 9-Carboxynonyl [7] ◯ ◯ Ex. 3-61hydrothermal 400 40 10 9-Carboxynonyl — [14]  ◯ ◯ Ex. 3-62 synthesis 40040 10 Octyl Decyl 9-Carboxynonyl [8] ◯ ◯ Ex. 3-63 400 40 10 [8] ◯ ◯ Ex.3-64 400 40 10 [7] ◯ ◯ Ex. 3-65 400 40 10 — [5] ◯ ◯ Ex. 3-66 400 40 10[5] ◯ ◯ Ex. 3-67 400 40 10 [5] ◯ ◯ Ex. 3-68 400 40 10 — ◯ ◯

TABLE 14 Formulations Inorganic substance High-temperature treatmentconditions and/or complex Organic compound Surface Reaction AmountAmount Water treatment Temp. Pressure time g(mL) g(mL) mL method ° C.MPa Min. Ex. 3-69 Catalyst particles 0.1 Methanol (3.170) —High-temperature 300 40 180 of Example 3-57 methanol Ex. 3-70 Catalystparticles 0.1 (3.170) treatment 300 40 180 of Example 3-61 Ex. 3-71Catalyst particles 0.1 (3.170) 300 40 180 of Example 3-27 Comp. Ex. 3-150 wt % aqueous 1 — 3.423 Hydrothermal 200 40 10 titanium (IV) treatmentComp. Ex. 3-2 bis(ammonium 1 1.617 400 40 10 lactato)dihydroxidesolution Comp. Ex. 3-3 Ti complex 0.5 2.617 400 40 10 (ligand:2-hydroxyoctanoic acid) Comp. Ex. 3-4 Ammonium oxalate 0.5 4.423 200 3010 Comp. Ex. 3-5 monohydrate 0.5 2.617 400 40 10 Catalyst particlesAverage Evaluation Inorganic particle Photocatalytic Resin particlesOrganic group on surface nm action degradation Ex. 3-69 TiO₂ 2-(Methoxy-5-(Methoxy- [2 to 10] ◯ ◯ carbonyl)ethyl carbonyl)pentyl Ex. 3-709-(Methoxy- [14] ◯ ◯ carbonyl)nonyl Ex. 3-71 9-(Methoxy- —  [3] ◯ ◯carbonyl)nonyl Comp. Ex. 3-1 TiO₂ — [30] ◯ X Comp. Ex. 3-2 [100]  ◯ XComp. Ex. 3-3 [10 to 140] ◯ X Comp. Ex. 3-4  [4] ◯ X Comp. Ex. 3-5 [50]◯ X

TABLE 15 High-temperature Formulations treatment conditions Inorganicsubstance and/or complex Organic compound Surface Amount Amount AmountWater treatment Temp. g(mL) g(mL) g(mL) mL method ° C. Ex. 3-72 Tungsticacid 0.50 — Decylamine 0.2164 4.207 Second 200 Ex. 3-73 0.50 Pd 0.0050.2164 4.207 hydrothermal 200 Ex. 3-74 0.50 Pt 0.005 0.2164 4.207synthesis 200 Ex. 3-75 0.50 Copper formate 0.06 0.2164 4.207 200 Comp.Ammonium 0.50 — — 4.423 200 Ex. 3-6 tungstate Comp. pentahydrate 0.502.617 400 Ex. 3-7 Comp. Tungstic acid 0.50 4.423 200 Ex. 3-8 Comp. 0.504.423 200 Ex. 3-9 Comp. 0.50 2.617 400 Ex. 3-10 Comp. 1.00 2.617 400 Ex.3-11 Comp. 0.50 Copper sulfate 0.01 2.607 400 Ex. 3-12 Comp. 0.50 0.102.517 400 Ex. 3-13 High-temperature Catalyst particles treatmentconditions Average Reaction particle Evaluations Pressure time InorganicOrganic group size Photocatalytic Resin MPa Min. particles on surface nmaction degradation Ex. 3-72 30 60 WO₃ Decyl [50] ◯ ◯ Ex. 3-73 30 60WO₃/Pd [50] ◯ ◯ Ex. 3-74 30 60 WO₃/Pt [50] ◯ ◯ Ex. 3-75 30 60 WO₃/Cu[50] ◯ ◯ Comp. 30 10 WO₃ —  [5] ◯ X Ex. 3-6 Comp. 40 10 [100]  ◯ X Ex.3-7 Comp. 30 10 [20] ◯ X Ex. 3-8 Comp. 30 60 [60] ◯ X Ex. 3-9 Comp. 4010 [100]  ◯ X Ex. 3-10 Comp. 40 10 [100]  ◯ X Ex. 3-11 Comp. 40 10WO₃/CuO — ◯ X Ex. 3-12 Comp. 40 10 [200]  ◯ X Ex. 3-13

TABLE 16 Formulations Inorganic substance and/or complex Organiccompound Amount Amount Amount Amount g(mL) g(mL) g(mL) g(mL) Ex. 3-76 50wt % aqueous 0.5 Sr(OH)₂ • 8H₂O 0.5 — Octylphosphonic 0.328 — titanium(IV) acid diethyl bis(ammonium ester lactato)di- hydroxide solution Ex.3-77 Ammonium 0.5 0.5 0.328 oxalate monohydrate Ex. 3-78 Ti complex 0.50.5 0.328 (ligand: 2-hydroxy- octanoic acid) Ex. 3-79 50 wt % aqueous0.5 0.5 6-Phosphono- 0.488 Octylphosphonic titanium (IV) hexanoic aciddiethyl bis(ammonium acid ester lactato)di- Ex. 3-80 hydroxide 0.5 0.5Nickel (II) 0.065 Octylphosphonic 0.3275 — solution acetate acid diethyltetrahydrate ester Ex. 3-81 0.5 0.5 Tris(acetyl- 0.104 0.3275acetonato)ru- thenium (III) Ex. 3-82 0.5 0.5 Nickel (II) 0.013 0.3275acetate tetrahydrate Ex. 3-83 0.5 0.5 Tris(acetyl- 0.021 0.3275acetonato)ru- thenium (III) High-tempereature treatment conditionsCatalyst particles Reac- Average Evaluation Formulations Surface Pres-tion particle Photo- Resin Amount Water treatment Temp. sure timeInorganic size catalytic degra- g(mL) mL method ° C. MPa Min. particlesOrganic group on surface nm action dation Ex. 3-76 2.289 Second 400 4010 SrTiO₃ Octyl — — ◯ ◯ Ex. 3-77 2.289 hydrothermal 400 40 10 ◯ ◯ Ex.3-78 2.289 synthesis 400 40 10 ◯ ◯ Ex. 3-79 0.3275 1.801 400 40 106-Phenylhexyl Octyl ◯ ◯ Ex. 3-80 2.289 400 40 10 SrTiO₃/NiO Octyl — ◯ ◯Ex. 3-81 2.289 400 40 10 SrTiO₃/RuO₂ ◯ ◯ Ex. 3-82 2.289 400 40 10SrTiO₃/NiO ◯ ◯ Ex. 3-83 2.289 400 40 10 SrTiO₃/RuO₂ ◯ ◯

Preparation Examples, Comparative Preparation Examples, Examples andComparative Examples Corresponding to the Fourth Group of Inventions

The fourth group of inventions will be described below in further detailby showing Preparation Examples, Comparative Preparation Examples,Examples and Comparative Examples, but the fourth group of inventions isnot limited thereto.

Evaluation methods performed on organic-inorganic composite particles,films (films (particle-containing resin molded articles) beforeextraction), and porous films (micropore resin compositions) will bedescribed below.

(1) X-Ray Diffractometry (XRD)

Organic-inorganic composite particles were loaded into a glass holderand subjected to X-ray diffractometry under the following conditions.After that, from the obtained peaks, the components of the inorganicsubstance were assigned by database search.

X-ray diffractometer: D8 DISCOVER with GADDS, available from Bruker AXS

(Optical system on incident side)

X-ray source: CuKα (λ=1.542 Å), 45 kV, 360 mA

Spectroscope (monochromator): multilayer mirror

Collimator diameter: 300 μm

(Optical system on light-receiving side)

Counter: two-dimensional PSPC (Hi-STAR)

Distance between organic-inorganic composite particles and counter: 15cm

2θ=20, 50, 80 degrees, ω=10, 25, 40 degrees, Phi=0 degrees, Psi=0degrees

Measurement time: 10 minutes

Assignment (semiquantitation software): FPM EVA, available from BrukerAXS

(2) Fourier Transform Infrared Spectrophotometry (FT-IR)

Fourier transform infrared spectrophotometry was carried out onorganic-inorganic composite particles according to the KBr method usingthe following apparatus.

Fourier transform infrared spectrophotometer: FT/IR-470Plus, availablefrom JASCO Corporation

(3) Average Particle Size Measurement by Dynamic Light Scattering (DLS)

A particle dispersion (with a concentration of solids of 1 mass % orless) was prepared by dispersing organic-inorganic composite particlesin a solvent, and the average particle size of the organic-inorganiccomposite particles in the particle dispersion was measured with adynamic light scattering photometer (model: ZEN 3600, available fromSysmex Corporation).

As the solvent, hexane was used in Preparation Example 4-1, chloroformwas used in Preparation Examples 4-2, 4-3, 4-5 and 4-6, and aqueousammonia having a concentration of 1 mass % was used in PreparationExample 4-4.

(4) Observation with Transmission Electron Microscope (TEM)

A film (film (particle-containing resin molded article) beforeextraction) was cut, and the cut surface was observed with atransmission electron microscope (TEM, H-7650, available from HitachiHigh-Technologies Corporation) for the dispersed state oforganic-inorganic composite particles in the film.

Also, the concentration distribution in the thickness direction ofmicropores was observed.

Here, for a clear view of the cut surface of the film, the film wasembedded in epoxy resin before cutting (machining).

Also, a particle dispersion (with a concentration of solids of 1 mass %or less) obtained by diluting organic-inorganic composite particles witha solvent was applied dropwise onto a TEM grid (collodion film, carbonsupport film) and dried. Then, the organic-inorganic composite particleswere observed with a transmission electron microscope (TEM, H-7650,available from Hitachi High-Technologies Corporation) and the averageparticle size of the organic-inorganic composite particles wascalculated by image analysis.

(5) Observation with Optical Microscope

The dispersed state of organic-inorganic composite particles in a filmwas observed with an optical microscope in the same manner as in theobservation with TEM described above.

(6) Clarity

Clarity of a porous film was visually observed and evaluated.

(7) Refractive Index

The refractive index of a porous film was measured using a prism coupler(SPA-4000, available from Sairon Technology, Inc.).

Specifically, the porous film was placed on a silicon wafer, andmeasurement was carried out.

The refractive index of the film was measured using light having awavelength of 633 nm.

(8) Reflectance

The reflectivity (wavelength: 550 nm) of a porous film was measuredusing Hitachi spectrophotometer U-4100 (available from HitachiHigh-Technologies Corporation).

(9) Dielectric Constant

The dielectric constant of a porous film was measured using TR-100automatic dielectric loss measurement apparatus (available from AndoElectric Co., Ltd.). The dielectric constant was measured at a frequencyof 1 MHz.

(10) Elongation at Break

The elongation at break of a porous film was measured using a tensiletester (trade name, STM-T-50BP, available from Toyo Baldwin Co. Ltd.)

Specifically, a sample having a width of 5 mm and a length of 100 mm wasmade from the porous film, and elongation was measured using theabove-mentioned tensile tester, with a chuck distance of 50 mm and apulling speed of 5 mm/min.

Preparation of Organic-Inorganic Composite Particles Preparation Example4-1

Cerium hydroxide (Ce(OH)₄, available from Wako Pure Chemical Industries,Ltd.) as an inorganic material, decanoic acid and hexanoic acid asorganic compounds and water were introduced into a 5 mL high-pressurereactor (available from AKICO Corporation) in amounts presented in Table17.

Next, the high-pressure reactor was closed with a cover, heated to 400°C. in a shaking furnace (available from AKICO Corporation) so as topressurize the inside of the high-pressure reactor to 40 MPa, and thenshaken for 10 minutes for hydrothermal synthesis.

After that, the high-pressure reactor was plunged into cold water forquenching.

Next, ethanol (available from Wako Pure Chemical Industries, Ltd.) wasadded, and the mixture was stirred and subjected to centrifugalseparation performed in a centrifuge (trade name: MX-301, available fromTomy Seiko Co., Ltd.) at 12000 G for 20 minutes to separate into aprecipitate (reaction product) and a supernatant (washing step). Thiswashing operation was repeated 5 times. After that, ethanol in theprecipitate was heated and dried at 80° C. to give organic-inorganiccomposite particles in which a decyl group and a hexyl group were boundto the surface of cerium oxide (CeO₂).

Next, the organic-inorganic composite particles obtained above andchloroform were introduced into a 50 mL centrifuge tube, and the mixturewas subjected to centrifugal separation performed in a centrifuge (tradename: MX-301, available from Tomy Seiko Co., Ltd.) at 4000 G for 5minutes to separate into a supernatant and a precipitate (wetclassification).

Next, the supernatant was removed therefrom and dried to giveorganic-inorganic composite particles having a small average particlesize.

After that, the obtained organic-inorganic composite particles wereevaluated by XRD, FT-IR, DLS and TEM described above.

As a result, XRD confirmed that the inorganic substance forming theinorganic particles was CeO₂.

Also, FT-IR confirmed that there were saturated aliphatic groups (adecyl group and a hexyl group) on the surface of the inorganicparticles.

Furthermore, DLS showed that the organic-inorganic composite particleshad an average particle size of 7 nm.

The above results are presented in Table 17.

TABLE 17 Formulations Inorganic substance and/or complex Organiccompound Preparation Amount Amount Amount Pure water Example g(mL) g(mL)g(mL) Amount(mL) Pre. Ex. 4-1 Ce(OH)₄ 1.09 Decanoic acid 0.5181 Hexanoicacid 0.3279 1.771 Pre. Ex. 4-2 Ce(OH)₄ 1.09 Decanoic acid 1.0362 — 1.01Pre. Ex. 4-3 Zn(CH₃COO)₂ 0.5 Ethyl 0.182 Ethyl 0.1638 2.453decylphosphonate octylphosphonate [2 mol/L aqueous KOH solution] Pre.Ex. 4-4 Ti complex (ligand: 0.5 Ethyl 0.182 Ethyl 0.1638 2.4532-hydroxyoctanoic acid) decylphosphonate octylphosphonate Pre. Ex. 4-5SrCO₃ 0.5 6-Phenylhexanoic 0.3503 — 3.403 acid Pre. Ex. 4-6 BaSO₄ 0.5Decanoic acid 0.2500 Hexanoic acid 0.1000 3.403 High-temperaturetreatment conditions Organic-inorganic composite particles ReactionComposition of Average Preparation Temp. Pressure time inorganicparticle Example ° C. MPa Min. particles *1 Organic group on surface *2size (nm) *3 Pre. Ex. 4-1 400 40 10 CeO₂ Decyl group Hexyl group  4 to10 [7] Pre. Ex. 4-2 400 40 10 CeO₂ Decyl group — 3 to 8 Pre. Ex. 4-3 40040 10 ZnO Decyl group Octyl group  4 to 20 Pre. Ex. 4-4 400 40 10 TiO₂Decyl group Octyl group 4 to 8 Pre. Ex. 4-5 300 30 10 SrCO₃6-Phenylhexyl group — 30 to 80 Pre. Ex. 4-6 300 30 10 BaSO₄ Decyl groupHexyl group 30 to 80

The matters specified by asterisks in Table 17 will be described below.

-   -   1: The composition was confirmed by XRD.    -   2: The organic groups were confirmed by FT-IR.    -   3: The average particle size was measured by TEM. It should be        noted that each value within parentheses “( )” indicates the        result obtained from measurement by DLS.

Preparation Examples 4-2 to 4-6

Organic-inorganic composite particles were prepared in the same manneras in Preparation Example 4-1, except that the formulation (amounts) ofthe inorganic material, the organic compounds and water (or aqueous pHadjusting solution) was changed to the formulations presented in Table17, and then subjected to washing and wet classification.

After that, the obtained organic-inorganic composite particles wereevaluated in the same manner as in Preparation Example 4-1. The resultsare presented in Table 17.

Comparative Preparation Examples 4-1 to 4-6

Untreated inorganic particles (or in other words, inorganic particlesthat had not been subjected to a high temperature treatment) wereprepared as inorganic particles for use in Comparative PreparationExamples 4-1 to 4-6, and used as inorganic particles in ComparativeExamples 4-1 to 4-12, which will be described later (see Table 20).

Preparation of Particle-Containing Resin Compositions, Production ofFilms and Production of Porous Films Example 4-1

A resin solution having a concentration of solids of 10 mass % wasprepared by blending polyetherimide resin (model: Ultem 1000, availablefrom SABIC Innovative Plastics Japan LLC) with chloroform.

Also, a particle dispersion having a concentration of solids of 10 mass% was prepared by blending the organic-inorganic composite particlesobtained in Preparation Example 4-5 (inorganic substance: SrCO₃, organicgroup: 6-phenylhexyl group) with chloroform.

Next, the resin solution and the particle dispersion were blended suchthat the proportion of resin relative to organic-inorganic compositeparticles was those presented in Table 18, and stirred with anultrasonic disperser. In this manner, a clear varnish ofparticle-containing resin composition was prepared.

Next, the obtained varnish was applied to a substrate (glass substratehaving a thickness of 1100 μm) by spin coating. Chloroform was mostlyvolatilized during application of the varnish.

After that, the applied particle-containing resin composition was driedat 50° C. for one hour (first drying) and then dried at 100° C. for 10minutes (second drying) to give a 15 μm thick film (particle-containingresin molded article).

After that, the obtained film was evaluated by TEM described above (thedispersed state and average particle size of organic-inorganic compositeparticles). The results are presented in Table 17 (average particlesize) and Table 18.

After that, the obtained film was peeled off from the substrate, andthen the organic-inorganic composite particles were extracted from theresin under the extraction conditions shown in Table 18.

In this extraction process, a nitric acid ethanol solution serving as anextraction solvent permeated through the resin and dissolved theorganic-inorganic composite particles.

As a result, micropores were formed in the resin, and a porous film(resin molded article) having the micropores was obtained.

After that, the obtained porous films were evaluated in terms of TEM(the presence of concentration distribution in the thickness direction),clarity, refractive index, reflectance, dielectric constant andelongation at break described above. The results are presented in Table18.

Examples 4-2 to 4-15 and Comparative Examples 4-1 to 4-12

Porous films were obtained by producing films in the same manner as inExample 4-1, except that the formulation of the resin solution and theparticle dispersion was changed to the formulations presented in Tables18 to 20, and then extracting organic-inorganic composite particlesunder the extraction conditions presented in Tables 18 to 20.

In Examples 4-8 and 4-9, the film was immersed in the extraction solventtogether with the substrate without the film being peeled off from thesubstrate.

In Comparative Examples 4-5 to 4-12, it was not possible to obtainself-standing porous films because the porous film was significantlydamaged when peeled from the substrate and lost flexibility.

The obtained films (films (particle-containing resin molded articles)before extraction) and porous films were evaluated in the same mannerdescribed above.

Image-processed TEM micrographs obtained in Examples 4-6, 4-7 and 4-13are shown in FIGS. 27 to 29, respectively.

TABLE 18 Example Example 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 ParticleOrganic-inorganic Preparation Composition of Organic group dispersed-composite particles *4 Example inorganic on surface resin (parts bymass) particles composition Preparation CeO₂ Decyl group Hexyl group — —— — — — — — — Example 4-1 Preparation CeO₂ Decyl group — — — — — — — — —— Example 4-2 Preparation ZnO Decyl group Octyl group — — — — — — — — —Example 4-3 Preparation TiO₂ Decyl group Octyl group — — — — — — — — —Example 4-4 Preparation SrCO₃ 6-Phenylhexyl group — 30 30 30 50 50 50 5050 50 Example 4-5 Preparation BaSO₄ Decyl group Hexyl group — — — — — —— — — Example 4-6 Resin *5 Polyetherimide resin 70 — — — — — — — —(parts by mass) Thermoplastic fluorine-based polyimide resin — 70 — — —— — — — Polyarylate — — 70 50 50 50 50 50 50 Extraction Presence ofsubstrate No No No No No No No Yes Yes conditions Extraction liquid *6Nitric acid ethanol solution Extraction state Dis- Dis- Dis- Dis- Dis-Dis- Dis- Dis- Dis- solved solved solved solved solved solved solvedsolved solved Extraction temperature (° C.) 60 60 60 80 60 20 20 20 20Extraction time (hr) 1 1 1 1 1 1 0.5 0.5 3 Resin Evaluation TEM State oforganic-inorganic composite Dispersed as primary particles moldedparticles in film (particle-containing article resin molded article) *9(porous Presence of micropores Yes film) Presence of concentrationdistribution No No No No No No Yes Yes Yes in thickness direction ofmicropores Visual inspection Clarity *10 ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ Refractiveindex Wavetngth 633 nm 1.56 1.46 1.44 1.4 1.4 1.4 1.39/1.49 *7 1.41/1.49*8 — Reflectance (%) Wavetngth 550 nm — — — — — 3.5 <3.5 <3.5 —Dielectric Measurement frequency 1 MHz 3.0 2.6 2.8 2.6 2.6 2.6 2.7 2.72.6 constant Mechanical Elongation at break *11 ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯ ◯strength

TABLE 19 Example Example 4-10 4-11 4-12 4-13 4-14 4-15 ParticleOrganic-inorganic Preparation Composition Organic group dispersed-composite Example of inorganic on surface resin particles *4 particlescomposition (parts by mass) Preparation CeO₂ Decyl group Hexyl group 8080 — — — — Example 4-1 Preparation CeO₂ Decyl group — — — 70 — — —Example 4-2 Preparation ZnO Decyl group Octyl group — — — 70 — — Example4-3 Preparation TiO₂ Decyl group Octyl group — — — — 70 — Example 4-4Preparation SrCO₃ 6-Phenylhexyl — — — — — — — Example 4-5 groupPreparation BaSO₄ Decyl group Hexyl group — — — — — 80 Example 4-6 Resin*5 Polyetherimide resin — — — — — — (parts by mass) Thermoplasticfluorine-based polyimide resin — — — — — — Polyarylate 20 20 30 30 30 30Extraction Presence of substrate No No No No No No conditions Extractionliquid *6 Hexane Extraction state Dis- Dis- Dis- Dis- Dis- Dis- persedpersed persed persed persed persed Extraction temperature (° C.) 20 6060 60 60 20 Extraction time (hr) 1 1 1 1 1 1 Resin Evaluation TEM Stateof organic-inorganic composite Bicontinuous phase separated structuremolded particles in film (particle-containing article resin moldedarticle) *9 (porous Presence of micropores Yes film) Presence ofconcentration distribution No No No No No No in thickness direction ofmicropores Dielectric Measurement frequency 1 MHz 25 25 25 25 25 25constant Mechanical Elongation at break *11 ◯ ◯ ◯ ◯ ◯ ◯ strength

TABLE 20 Comparative Example Comparative Example 4-1 4-2 4-3 4-4 4-5 4-64-7 4-8 4-9 4-10 4-11 4-12 Particle Organic-inorganic ComparativeComposition Organic dispersed- composite particles *4 Preparation ofinorganic group on resin (parts by mass) Example particles surfacecomposition Comparative CeO₂ — — — — — — — — 80 — — — — PreparationExample 4-1 Comparative ZnO — — — — — — — — 80 — — — Preparation Example4-2 Comparative TiO₂ — — — — — — — — — 80 — — Preparation Example 4-3Comparative SrCO₃ 30 — — — — — — — — — 80 — Preparation Example 4-4Comparative BaSO₄ — — — — — — — — — — — 80 Preparation Example 4-5Comparative Al₂O₃ — 30 30 30 80 80 80 — — — — — Preparation Example 4-6Resin *5 Polyetherimide resin — 70 — — 20 — — — — — — — (parts by mass)Thermoplastic fluorine-based polyimide resin — — 70 — — 20 — — — — — —Polyarylate 70 — — 70 — — 20 20 20 20 20 20 Extraction Presence ofsubstrate No No No No No No No No No No No No conditions Extractionliquid *6 Nitric acid Hexane ethanol solution Extraction state Dis- Dis-Dis- Dis- Dis- Dis- Dis- Dis- Dis- Dis- Dis- Dis- solved persed persedpersed persed persed persed persed persed persed persed persedExtraction temperature (° C.) 20 20 20 20 20 20 20 20 20 20 20 20Extraction time (hr) 5 5 5 5 5 5 5 5 5 5 5 5 Resin Evaluation TEM Stateof organic-inorganic composite Coagulated molded particles in film(particle-containing article resin molded article) *9 (porous Presenceof micropores Yes film) Presence of cencentration distrobution No No NoNo No No No No No No No No in thickness direction of micropores Visualinspection Clarity *10 X X X X X X X X X X X X Reflectance (%)Wavelength 550 nm 10 10 10 10 — — — — — — — — Dielectric Measurementfrequency 1 MHz 28 3.1 27 29 — — — — — — — — constant MechanicalElongation at break *11 X X X X Self-standing film was not obtained dueto lack of flexibility strength

In Tables 18 to 20, the numerical values provided in “Organic-inorganiccomposite particles” indicate the amount of organic-inorganic compositeparticles in a particle dispersion, expressed in parts by mass, and thenumerical values provided in “Resin” indicate the amount of resin in aresin solution, expressed in parts by mass.

The following gives detailed description of resins presented in Tables18 to 20 and inorganic particles of Comparative Preparation Examples 4-1to 4-6 presented in Table 20, as well as description of the mattersspecified by asterisks.

<Resins>

Polyetherimide resin: Ultem 1000, refractive index (wavelength: 633 nm):1.63, reflectance (wavelength: 550 nm): 7%, dielectric constant: 3.2,available from SABIC Innovative Plastics Japan LLC

Thermoplastic fluorine-based polyimide resin: thermoplasticfluorine-based polyimide resin used in Example 1 of Japanese UnexaminedPatent Publication No. 2003-315541, refractive index (wavelength: 633nm): 1.52, reflectance (wavelength: 550 nm): 5%, dielectric constant:2.8

Polyarylate: polyarylate resin used in Example 4 of Japanese UnexaminedPatent Publication No. 2009-80440, refractive index (wavelength: 633nm): 1.49, reflectance (wavelength: 550 nm): 5%, dielectric constant:3.0

Inorganic Particles Comparative Preparation Examples 4-1 to 4-6

CeO₂: Comparative Preparation Example 4-1, average particle size 200 nm,available from Kojundo Chemical Lab. Co., Ltd.

ZnO: Comparative Preparation Example 4-2, average particle size 200 nm,available from Sakai Chemical Industry Co., Ltd.

TiO₂: Comparative Preparation Example 4-3, trade name SSP-25, averageparticle size 9 nm, available from Sakai Chemical Industry Co., Ltd.SrCO₃: Comparative Preparation Example 4-4, average particle size 200nm, available from Honjo Chemical Corporation

BaSO₄: Comparative Preparation Example 4-5, trade name BF40, averageparticle size 10 nm, available from Sakai Chemical Industry Co., Ltd.

AL₂O₃: Comparative Preparation Example 4-6, trade name AEROXIDO@AluC,average particle size 15 nm, available from Nippon Aerosil Co., Ltd.

<Specified Matters (*4 to *9)>

-   -   4: Prepared as a particle-dispersed chloroform solution having a        concentration of solids of 10 mass %. The numerical value        indicates the amount of solids expressed in parts by mass.    -   5: Prepared as a resin solution having a concentration of solids        of 10 mass %. The numerical value indicates the amount of solids        expressed in parts by mass.    -   6: A nitric acid ethanol solution having a concentration of 3.2        mass % prepared by mixing 50 parts by mass of 1 mol/L (6.3 wt %)        aqueous nitric acid solution and 50 parts by mass of ethanol.    -   7: Refractive indices obtained by calculation that indicate that        the surface refractive index was 1.39 and the internal        refractive index was 1.49.    -   8: Refractive indices obtained by calculation that indicate that        the refractive index of the exposed surface was 1.41 and the        refractive index of the substrate-side surface was 1.49.    -   9: Determined from TEM or optical micrographs.    -   10: Visually determined based on the following criteria.

A circle “∘” was given when the film was clear.

A cross “x” was given when the film was opaque.

-   -   11: Elongation at break was determined based on the following        criteria.

A circle “∘” was given when the elongation was 10% or greater.

A cross “x” was given when the elongation was less than 10%<

Examples and Comparative Examples Corresponding to the Fifth Group ofInventions

The fifth group of inventions will be described below in further detailby showing Examples and Comparative Examples, but the fifth group ofinventions is not limited thereto.

Evaluation methods performed on titanium complexes will be describedbelow.

<Evaluation Methods> (1) MALDI-TOF MS Measurement (MeasurementApparatus)

Autoflex available from Bruker Daltonics

(Measurement Conditions)

Laser light source: N₂ laser (wavelength: 337 nm)

Measurement modes: reflector mode, negative ion mode

Measured mass range (m/z): 20 to 3000

Number of scans: 1500 times

Matrix: Meso-tetrakis-(pentafluorophenyl)-porphyrin

Preparation of Titanium Complexes Example 5-1 Preparation of TitaniumComplex Containing 2-Hydroxyoctanoic Acid as Ligand

Under ice-cold conditions, 100 mL of 30 volume % hydrogen peroxidesolution (available from Wako Pure Chemical Industries, Ltd.) and 25 mLof 25 mass % aqueous ammonia (available from Wako Pure ChemicalIndustries, Ltd.) were mixed in a 500 mL beaker. Then, 1.5 g of titaniumparticles (available from Wako Pure Chemical Industries, Ltd.) wereadded thereto and the mixture was stirred for 3 hours under ice-coldconditions until complete dissolution. Next, 15.5 g of 2-hydroxyoctanoicacid dissolved in 50 mL of ethanol (titanium particles:2-hydroxyoctanoic acid=1:1.5 (molar ratio)) was added and the mixturewas stirred. After complete dissolution of all components, stirring wasstopped and the mixture was allowed to stand still for one day. Afterthat, the mixture was dried at 75° C. in a drier for 3 hours so as togive a water-soluble titanium complex.

The obtained water-soluble titanium complex was subjected to MALDI-TOFMS measurement. As a result, the obtained titanium complex wasidentified as a mixture composed of two titanium complexes representedby the following chemical formulas (3) and (4).

General Formula (3):

[Chemical Formula 1]

General Formula (4):

[Chemical Formula 2]

Example 5-2 Preparation of Titanium Complex Containing 3-HydroxydecanoicAcid as Ligand

A water-soluble titanium complex was obtained through the same treatmentas in Example 5-1, except that 18.2 g of 3-hydroxydecanoic acid(titanium particles: 3-hydroxydecanoic acid=1:1.5 (molar ratio)) wasadded instead of 15.5 g of 2-hydroxyoctanoic acid.

Comparative Example 5-1 Preparation of Titanium Complex Containing MalicAcid as Ligand

A water-soluble titanium complex was obtained through the same treatmentas in Example 5-1, except that 13.0 g of malic acid (titaniumparticles:malic acid=1:1.5 (molar ratio)) was added instead of 15.5 g of2-hydroxyoctanoic acid.

Comparative Example 5-2 Preparation of Titanium Complex ContainingGlycolic Acid as Ligand

A water-soluble titanium complex was obtained through the same treatmentas in Example 5-1, except that 7.2 g of glycolic acid (titaniumparticles:glycolic acid=1:1.5 (molar ratio)) was added instead of 15.5 gof 2-hydroxyoctanoic acid.

Preparation of Titanium Oxide Particles Example 5-3

The titanium complex prepared in Example 5-1 in an amount of 0.5 g andwater in an amount of 2.3 g were introduced into a 5 mL high-pressurereactor (available from AKICO Corporation). Next, the high-pressurereactor was closed with a cover, and the titanium complex and water weretreated in a shaking furnace (available from AKICO Corporation) at 400°C. and 40 MPa for 10 minutes. After that, the high-pressure reactor wasplunged into cold water for quenching.

Next, ethanol (available from Wako Pure Chemical Industries, Ltd.) wasadded, and the mixture was stirred and subjected to centrifugalseparation performed in a centrifuge (trade name: MX-301, available fromTomy Seiko Co., Ltd.) at 12000 G for 20 minutes to separate aprecipitate (reaction product) from a supernatant (washing step). Thiswashing operation was repeated 5 times.

After that, ethanol in the precipitate was heated and dried at 80° C.,and thereby pale yellow white rutile titanium oxide particles (TiO₂)were obtained.

Example 5-4

Pale yellow white rutile titanium oxide particles (TiO₂) were obtainedin the same manner as in Example 5-3, except that the titanium complexprepared in Example 5-2 was used instead of the titanium complexprepared in Example 5-1.

Comparative Example 5-3

Brown titanium oxide particles (TiO₂) were obtained in the same manneras in Example 5-3, except that the titanium complex prepared inComparative Example 5-1 was used instead of the titanium complexprepared in Example 5-1.

Comparative Example 5-4

Brown titanium oxide particles (TiO₂) were obtained in the same manneras in Example 5-3, except that the titanium complex prepared in Example5-4 was used instead of the titanium complex prepared in Example 5-1.

Comparative Example 5-5

Brown titanium oxide particles (TiO₂) were obtained in the same manneras in Example 5-3, except that titanium peroxo citric acid ammoniumtetrahydrate (trade name: TAS-FINE, available from Furuuchi ChemicalCorporation) was used instead of the titanium complex prepared inExample 5-1.

While the illustrative embodiments of the present invention are providedin the above description, they are for illustrative purposes only andnot to be construed as limiting. Modification and variation of thepresent invention that will be obvious to those skilled in the art is tobe covered by the following claims.

INDUSTRIAL APPLICABILITY

The particle-containing resin molded article has various applicationsincluding, for example, optical applications such as flexiblesubstrates, electronic and electrical applications, mechanicalapplications and the like. When used in electronic and electricalapplications, the particle-containing resin molded article is used as,for example, an optical fiber, an optical disc, a light guide plate, ora flexible substrate such as an optical film.

The particle-dispersed resin composition and the particle-dispersedresin molded article are used in various industrial applicationsincluding optical applications.

Also, the catalyst molded article containing catalyst particles can beused as, for example, an optical film such as a polarizing film, aretardance film, a brightness enhancing film, a viewing angle enhancingfilm, a high-refractive index film or a light diffusing film; or aconstruction material (construction) film such as an ultravioletabsorbing film, a dirt repellent film, an antimicrobial film, adeodorizing film, a super-hydrophilic film, a germicidal film, adetoxification film or a chemical substance decomposing film.

Also, the resin molded article is used as a porous film in opticalapplications including optical films such as a low-refractive film andan antireflective film, as well as electrical and electronicapplications including electrical and electronic substrates such as alow-dielectric substrate. Alternatively, the resin molded article isused as a film having paths formed by communicating pores in variousapplications including sizing filters, molecular separation membrane,adsorptive separation filters and electrolyte membranes.

Also, the titanium complex is used in production of, for example,titanium oxide particles, and the titanium oxide particles are used in,for example, various industrial products for optical applications or thelike.

1. Catalyst particles comprising inorganic particles with a catalyticaction and an organic group that binds to the surface of the inorganicparticles, and having a configuration that does not allow the inorganicparticles to contact with each other by steric hindrance of the organicgroup.
 2. The catalyst particles according to claim 1, having acatalytic action for a gas and/or a liquid.
 3. The catalyst particlesaccording to claim 1, having a photocatalytic action for a gas and/or aliquid.
 4. The catalyst particles according to claim 1, dispersed asprimary particles in a solvent and/or a resin.
 5. The catalyst particlesaccording to claim 1, containing a plurality of mutually different typesof organic groups.
 6. The catalyst particles according to claim 1,wherein the organic group is bound to the surface of the inorganicparticles via a binding group, and the binding group contains aphosphoric acid group and/or a phosphoric acid ester group.
 7. Thecatalyst particles according to claim 1, wherein the inorganic particlescontain an oxide.
 8. The catalyst particles according to claim 1,wherein the inorganic particles contain at least one oxide selected fromthe group consisting of TiO₂, WO₃ and SrTiO₃.
 9. The catalyst particlesaccording to claim 8, wherein the inorganic particles further contain atleast one inorganic substance selected from the group consisting of Pt,Pd, Cu, CuO, RuO₂ and NiO.
 10. The catalyst particles according to claim1, wherein the catalyst particles have an average maximum length of 450nm or less.